A long steel manufacturer needed to spray a rust inhibitor on polished steel bars. However, its air atomizing spray system was creating misting, overspray and over-application of the oil. These issues resulted in messy equipment, an unsafe production area and an unhealthy environment for workers. The company required a new rust inhibitor spraying system that would improve the precision of oil application. In turn, this system would also reduce material and labor expenses.
Rust inhibitor spraying system
Following a test using hydraulic spray nozzles to check for spray pattern accuracy, we installed an AutoJet® E1850+ Spray System. The system also includes three PulsaJet® AA10000AUH-104215 electrically-actuated spray nozzles and UniJet® PWMD spray tips.
As the 7/8- to 3-inch-diameter steel bars pass through the spray station, the E1850+ system is triggered by a photoelectric thru beam sensor. This sensor starts and stops the spray nozzles. Mounted to deliver uniform, consistent oil coverage, these hydraulic nozzles were able to achieve a low flow rate of 4 to 15 liters/hour and steady liquid pressure of 2 bar.
Result
The AutoJet rust inhibitor spraying systems and PulsaJet hydraulic nozzles are now coating the steel bars without misting or overspray. This saves the manufacturer significant costs in rust inhibitor consumption, air compressor operation and maintenance. They also achieve major savings in labor for cleanup, and materials to absorb spills and excess spray. All of these reductions totaled € 17,500 annually, resulting in a payback period of less than a year for the new spray system.
The company also was able to improve its sustainability efforts by making the work environment safer and healthier for employees through the elimination of overspray and airborne oil.