CS 1 – OEM Emulsion Conversion

Situation

  • Customer’s original process was designed for emulsion chemistry but converted to a traditional water system due to high operating costs and limited capability with increased production
  • Previous competitor’s traditional program was unable to successfully operate five tank system – system had poor water quality/high suspended solids resulting in increased cleaning costs
  • The system’s inability to remove the paint solids caused booth balance issues and affected vehicle paint quality

Background

  • A new automotive assembly plant was constructed in the mid-2000’s
  • The paint booths were set up to run on an emulsion system rather than traditional water – thus the tanks had very small tank volumes, were shallow and had short retention times
  • A competitor attempted to operate the system without success. Galaxy was brought in when the customer wanted to improve their performance

Solution

  • Paint samples were screened against the Galaxy detack chemistries and the program with the best kill, clarity and floatation was selected
  • GCC 836, a high-performing product, was chosen based on the system’s operating challenges
  • Various application points were evaluated to mesh with the new sludge handling equipment – and the process was optimized
  • Brought in technology from the textile industry to deal with some of the customer’s challenges

Results

  • Galaxy was able to successfully transition the system to the Galaxy program, dramatically improving booth performance
  • System now operates with very low suspended solids (20-50 ppm) going back to the booths
  • Operating Cost per Unit well below competitive program

CS 1 – OEM Emulsion Conversion