Paint Booth Boosts Cleaning, Quality and Savings

CUSTOMER: Architectural aluminum systems manufacturer

GRACO EQUIPMENT: ProBell rotary bell atomizers

A leading architectural aluminum systems manufacturer produces a range of building solutions, from curtain walls and entrances to frames and windows. They use Graco ProBell rotary bell atomizers to spray primer onto 4 x 8 foot, 4 x 10 ft. and 4 x 12 ft. sections of extruded aluminum.

CHALLENGE: The paint line manager was satisfied with ProBell performance, but his team needed to take extra steps to ensure consistent, quality output. For example, technicians had to clean the front end of the rotary bell atomizers once a shift to avoid excessive paint buildup and meet the manufacturer’s high quality standards. Regular cleaning was especially critical during night shift, when there is no supervisor present.

Extruded aluminum sheets sometimes received a lighter amount of primer in the middle. To achieve an even coating, multiple passes were required.

Other times, uneven film buildup on 4 x 8 ft. extrusions caused zebra striping. Paint booth technicians had done everything to mitigate the stripes, including conducting booth airflow studies and frequently washing the bell cup.  

Finally, fluid delivery required 20 psi of pressure, and there was no way for technicians to lower it to reduce primer consumption.

SOLUTION: The paint line manager agreed to test the next generation of air caps for Graco ProBell rotary bell atomizers. Air cap installation in one paint booth quickly proved the upgrade’s value.

Now they could apply primer to extruded aluminum while leveraging the ProBell’s distinct advantages:

• Compact size and small diameter for tight spaces
• Power supply with low voltage to improve safety and reduce complexity
• Stainless steel air cap cover to protect bell and air cups
• Blended shaping air to provide a better finish quality

RESULTS: With the new Graco ProBell air cap, paint booth technicians can go an entire week without having to clean the front end of the rotary bell atomizer, saving labor and reducing device downtime with each shift.

While the paint line manager requires technicians to clean the applicator every two days as a precaution, the process is easier than ever: Simply remove the air cap, soak the applicator tip in solvent and then wipe off any remaining primer.

The ProBell upgrade produces a consistent, even paint pattern — reducing the number of passes needed for an even coat and eliminating the striping issue on the 4 x 8 ft. sheets.

A welcome surprise was the ability to reduce the fluid pressure from 20 psi to 10 psi. Because of the decreased pressure, paint booth technicians expect to see a significant reduction in the volume of paint sprayed.