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Newsletter 2004 issue 2 |
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Filtering Out Waste
Paint was “hanging” in the
booth, causing Crenlo’s painters to complain about overspray
and poor airflow.
“If anyone complained about booth
conditions, we changed out the filters rather than knowing
what our problem was, “ explained Jason Kleeberger, safety/environmental
specialist. “We had no set procedures.”
Crenlo LLC fabricates sheet metal
products, including agricultural and construction equipment
cabs and electronic enclosures.
Test panels located on the top of
the exhaust stacks showed paint, possibly indicating low paint-capturing
efficiency for the filters. The back layer of the filters
were discolored by paint making it look as if the filters
were loaded with overspray.
All of these factors led Crenlo to
change its paint filters daily. At roughly $1,000 a day, the
filters were exceeding the amount budgeted. Excessive maintenance
time was also required for filter change out. Crenlo requested
a MnTAP intern to help investigate and reduce its paint
filter waste and to decrease its wastewater volume.
The intern analyzed the system for
best set up. He tested different types of paint arrestors.
None of them performed better than the two different layered
grades of high efficiency/high capacity paper filters that
Crenlo was currently using.
The intern also experimented with
the frequency of filter change out. Depending on the paint
line, he was able to extend the use of the top filters to
three or five days without measurable change in efficiency.
The bottom filters could last 12 days.
Based on production levels at the
time of the intern project, modifying the paint filter change
out schedule saved Crenlo $95,600 a year. Filter purchase
cost was reduced by $88,200 and waste disposal was reduced
by 21 tons a year, saving $7,400. Over 1,500 hours of maintenance
labor was no longer needed to change out filters. Crenlo also
made booth repairs to prevent air leaks.
The challenge for the intern was dealing
with busy maintenance supervisors. “If Yafet [the intern]
came to talk to you, he’d ask one or two questions. Yafet
was able to get the information he needed—fast,”
said Kleeberger. “He could work on his own. You didn’t
have to hold his hand.”
More information on paint filters
is available in Paint
Filters: Crenlo saves Nearly $100,000 by Reducing Paint Filter
Waste and Water. Intern program application deadline for
2005 is March 1; see the MnTAP
Intern Program Web page.
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