Case
Study
AUTOMOTIVE BODY SHOPS
Switch to HVLP Spray Equipment
| Company | Colorado Coach Autobody 4850 Valmont Road, Boulder, CO 80301 |
|---|---|
| Person to Contact | Paul Amara Telephone: (303) 449-4153 |
| Product or Service | Autobody Repair |
| Number of Employees | 30 |
| Waste Stream Targeted | Coatings Material Usage, VOCs (solvent emissions) |
| Original System | Conventional Air Atomized Spray Guns require compressed air of 35 to 80 psig to atomize coatings. As the compressed air is released from the gun, it expands and propels the coating, then returns to atmospheric pressure. The rapid expansion of spray caused by higher air pressure results in excessive over spray, higher VOC emissions, and a transfer efficiency of 25-30%. |
| New System (with P2 Modifications) |
High Volume Low Pressure Spray Guns (HVLP, Sata N92) with gravity feed paint cups. Requires 0.1 to 10 psig air pressure for atomization. Generates high volumes of low pressure air which transfers the coating to the substrate with low velocity and prevents the rapid expansion of spray resulting in less over spray, lower VOC emissions, and better transfer efficiency (40-70%) in autobody repair. Mixed paint (primer, base coat, and clear coat use) is fed directly into the spray gun via a gravity flow cup located on top of the paint gun, resulting in little paint loss from the cup into the spray gun (versus siphon paint cups which siphon paint into the gun from below resulting in paint loss from the bottom of the cup). |
| Cost Savings | |
| Initial Equipment Costs | Colorado Coach purchased five new HVLP spray guns at $435 each (or $2,175 total cost). The new guns were the only initial equipment costs since the old compressed air system and lines were modified to operate with the new HVLP guns. |
| Material Cost Savings | Total materials costs (paints, additives, hardeners, primers, reducers, thinners, etc) average $20,000 per month. Since implementation of the new HVLP system, there has been a ~ $5,000/month or $60,000/yr savings in total materials costs or ~ 25%. |
| Payback Period | Payback on the new HVLP equipment purchase of less than 2 weeks! |
| Major Benefits | 25% savings in total materials costs or a cost savings of
$60,000 per year. Reduced VOC emissions by 25%. Good paint quality. Improves the company's public image by recognition as a "Business Partner for a Clean Environment" by the City/County of Boulder. |
| Obstacles | Some Employee adjustment. Adjustment to new HVLP equipment took
very little time/training. Labor costs have not changed since
implementation of the HVLP spray guns. Paint quality has not been a problem. |
| Time Since Implementation | 6 months (10/5/95) |
| Source/Supplier | Sikkens (Akzo-Nobel Coatings) 4105 Holly Street, Denver, CO 80216 Telephone: (303) 329-6077 |
| Main Reason Implemented | Cost savings and reductions in VOC emissions, public recognition. |
| Key to Success in Making this P2 Modification | P2 Workshop and P2 assistance from Dave Swanson, Boulder County
Pollution Prevention Program, (303) 441- 1146. Vendors were very helpful in supplying information on spray gun equipment and paint products. Management support for pollution prevention. |
Created by Lighthouse Communications Group, LLC.
Edited for use on this site by Ronald Lee Still and posted with
permission of CDPHE.