Making robotic paint automation pay.  GUARANTEED!


North American Paint Applications

Specializing in Industrial Paint Process Optimization



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Products & Services

  - Paint Process Optimization

  - Paint System Audit

  - Paint System Specification

    a Paint Color Change Efficiency

    a Paint Shop Throughput

    a Paint Overspray Reduction

    a Painting Robot Paths

    a Paint Finish Quality

    a Paint System Troubleshooting

    a Painting System Automation

  - Paint Supply & Delivery Systems

    a Dead Head Paint Supply

    a Recirculating Paint Supply

    a Flexible Colors Paint Delivery

    a Piggable Paint Supply System

    a Self-Flushing Paint Systems

    a Oil Free Paint Supply

    a Paint Sheer Reduction

    a Spray Booth Waste Collection

  - RoboGuide PaintPro Simulation 

  - ABB RobotStudio for Paint

  - Paint Flow Control

  - 2 or 3K Paint Dispensing Systems



Since 2008, our customers have created over a thousand jobs in paint finishing, opened new facilities, expanded existing ones, and brought millions in production back to the USA.  Improved paint finishing operations have added greater than $300 million to their businesses.  The average NAPaint project ROI is less than 5 months.  Annual benefit can exceed tens of millions.





A color change is the purging of one color from the paint applicator and the loading of a second color.  Sometimes, it includes a paint push out.  Color changes affect quality, throughput, waste, and maintenance and can have a severe impact on the overall productivity of paint processes.  Whether you have a manual color change or an automatic color change, you may find the discussion below useful to both operator and maintenance personnel and as an aid to management in making the right decisions .


North American Paint Applications is the world leader in implementation of efficient color changes for every type of application.  





When changing colors, the equipment is not painting.  It follows then that the longer the duration to complete the color change process, the lower the part throughput of the system.  Long color changes often have a negative impact on productivity.


As an estimate in automated systems, typical color change times are one second per foot of paint hose from the color valve stack to the applicator.  Manual systems vary widely.  With efficient design, faster color change times can be easily achieved.  An integrated color change and cap clean that begins at the last trigger off can save 5 to 10 seconds of cycle time.





Automated color changes ought to be designed to purge and load the lines efficiently, repeatably, and with sufficient flexibility to make allowances for all purging and loading variations among the different materials.  For example, it is common that white may be more difficult to purge than black and may take longer to load.  The system ought to be flexible enough to support this.  


Problems such as color carryover, insufficient paint load, sputtering, and overspray contamination should never occur when equipment is functioning as designed.  The system should be repeatable for any combination.  





Unless a paint push out is incorporated, all material used during a color change is waste and must be disposed of.  In automatic color changes, it is normally collected via piping direct to waste storage.  Only a minimal amount of waste material required to clean the bell or gun is normally sprayed into the booth.


The amount of material used for color change depends on many factors, including paint line length and size, paint and solvent chemistry, equipment, and method of implementation.  Paint is the most expensive material of the waste and the amount used should never be greater than 120% of the internal volume of the piping system from the color valve stack to the applicator, and less if a paint push out is used.  For solvent, a good benchmark would be less than one cup per 5 feet of paint line.  





Paint push out refers to the process of 'pushing' paint out of the lines and onto the part prior to a color change.  This is usually done with solvent.  In this way, less paint is wasted during a color change and color change times are shortened.





Many facilities depend upon labor to implement a color change.  While this may seem most economical at first glance, there is a real cost associated with manual color changes that must be accounted for.


First, manual color changes usually take significantly longer than automated color changes.  If the conveyor must be stopped or gaps inserted to facilitate the change, throughput suffers.


Second, the operating cost of manual color changes is much higher than automatic color changes.  This results from increased labor costs, increased material costs, and increased waste handling and disposal.


Third, the quality of the color change is not certain to be repeated.


NA Paint is ready not only to automate your color change, but to optimize it.  A cost/benefit analysis must be performed, but it is our experience that in most applications automating will save large amounts of paint and solvent, emissions, reduce booth contamination and filter loading/sludge creation, improve quality and consistency, and increase paint shop throughput significantly.  We look forward to helping you analyze your existing process.








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