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Sample Painting Process Flow Chart
Paint Application
Paint application is a complete step, but there are
a number of factors that can affect waste generation,
paint consumption, and product quality.
This step generally
has large losses associated. In this case:
- 1,130 gpy of evaporation from parts
as well as from paint overspray
- 350 gpy of solids from overspray,
this is equivalent to 1,170 gpy of purchased paint
- 150 lb/yr of filter/paint arrester
waste
Prevention Planning
Paint application has no substeps,
but there are a number of factors that can affect waste
generation, paint consumption and product quality.
Sources of Waste, Inefficiency
and Cost
Evaporation losses of 1,095 gpy
come from paint drying on parts. Materials accounting
might show:
- Transfer efficiency is 49 percent.
This is quite good for a liquid painting operation.
Lower transfer efficiencies increase the incentives
for making improvements.
- Paint lost to overspray is the
equivalent of 1,095 gpy (value $11,000-$50,000/ year)
of purchased paint.
- Evaporation losses amount to 1,027
gpy from overspray. This is 50 percent of reportable
VOC and HAP emissions
- Much of the overspray is caught
on filters resulting in shorter filter life and greater
filter use.
- An estimated five percent of parts
painted need to be reworked. Cost of rework can include
the value of scrap product, the cost of reworking
the product ranging from spot sanding and touchup
to stripping and refinishing the part. A likely minimum
cost is the value of the paint used in the first pass,
or 120 gpy with a value of $1,200 to $6,000 a year.
Next steps would be to determine if
transfer efficiency improvements or rework reduction
should be evaluated, and then to identify the factors
that make transfer efficiency lower or rework higher
than it could be.
Plant operations for this example:
paint
preparation | part
preparation | paint application | paint
curing | paint
cleanup | assembly,
inspection & shipping
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P2 Planning
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