‘On Line’ Research Reveals Best Piggable Pump

CUSTOMER: Tier 1 Automotive Manufacturer

GRACO EQUIPMENT: Endura-Flo 4:1 Air Operated Diaphragm Pump

CHALLENGE: When the paint process manager at a major automotive plant received an obsolescence notification, he used it as an opportunity to do actual “on line” research.

The robotic paint line needed a new piggable pump that was:

• Durable, performing well under high flow and high pressure demands
• Low-maintenance, needing little attention and no regular re-torqueing by maintenance staff

He asked five finishing equipment brands (Binks, Graco, Kremlin, Timmer, Wilden) to provide candidates for the factory’s piggable paint circulation system. One brand provided two options; the rest offered one. 

SOLUTION: Over two years, six different pumps were installed on the paint line and scrutinized. Factors evaluated included:

• Air consumption
• Noise level
• Air motor oil consumption
• Surge pressure drop between strokes
• Loading capability with eight robots at the same time
• Runaway prevention
• Technical support – locally and from the original equipment manufacturer (OEM)

After four months, each pump was pulled off line, torn apart and inspected for wear and tear. Maintenance staff also examined:

• Cleanliness of internal components after pigging process purge
• Repair cost with estimated mean time to repair (MTTR)
• Maintenance documentation ease of use and part identification

RESULTS: Two pumps failed completely. Another pump fell apart and was shipped back to the supplier in a box.

Of the three remaining pumps, the Endura-Flo 4:1 proved the most durable, according to the paint process manager.

When maintenance staff inspected the Graco air operated diaphragm pump for wear and tear, they reported it “looked perfect when disassembled.”

In addition, DataTrak control prevented pump runaway and tracked material usage.

Five Endura-Flo pumps were installed on the piggable paint system. A year later, the paint process manager remains pleased with their durability.

• Durability means more uptime due to lower repair frequencies.
• Lower repair frequencies not only means less downtime or chance of failure during production, it also means maintenance does not need to keep many spare parts on hand.   

Endura-Flo worked so well on the robotic paint line, the air operated diaphragm pump was chosen for some booth-side feed applications. This brought up the number of Graco pumps in use at the Tier 1 automotive plant to more than 20.