Controlling Air Quality of Paint Lines

Managing an automotive paint line is challenging. The smallest factors can have serious consequences. Air quality is critical to every step of the process in a paint shop. Contaminated air can lead to expensive rework and even shut-downs of the line. It can significantly impact the “First-time Through Rate” and the overall production schedule of a vehicle.

Potential Causes of Defects Leading to Rework:

  • Ambient dust or process dust
  • Human hair
  • Textile fibres
  • Contaminants, such as silicone or PVC particles
  • Human error
  • Process error

Extensive Studies Show:

Required rework causes productivity to suffer:

  • Longer production schedules
  • Loss of profits due to add-on-processing
  • Negative impact on Key Performance Indicators
  • Increased operating costs for paint line


Managing Risks and Detecting Defects

There are significant costs associated with managing risks and detecting defects. Even when the most comprehensive precautions are taken, failures occur. Actual detection efficiency rates of trained human operators range from 80% to 90%. When robots are used to fill the role of human operators, detection efficiency rates increase to approximately 96%.

The Importance of Avoiding a Loss of Control Event

Once contaminated air particles cause a defect on a freshly painted surface, a Loss of Control Event is reached. This is the point at which costly rework is unavoidable.

Air Quality Management Is Critical to Maintaining a Fluid Supply Chain

Managing air quality for painting processes is critical to maintaining a fluid supply chain. Eliminating airborne dust contamination is essential to preventing failures which halt production, affecting both the upstream and downstream supply chain.

The first step in controlling air quality is installation of appropriate filters for all stages of the paint process. Early detection and effective management of contamination risks are key to minimizing production disturbances and reducing costs.


AAF Offers a True Consultative Approach

Paint shop operation teams need the support of a trusted on-site advisor who can perform air filtration audits, diagnostics, and continuous improvement to ensure the most optimal effective solution for cost savings and risk reduction. We do this by providing a consultative and technical approach to understanding your complete air filtration needs, application, and business goals, to optimize your performance and lower your total cost of ownership.

The paint shop is the most energy intensive step of car manufacturing. A full 75% of the total energy required for the process is used in the operation of the paint shop’s ovens and spray booths. To achieve the air quality required for optimal surface treatment results, large quantities of air are temperature treated and moved.


Equipment on Site

• Handheld laser-particle-counter with specific calibration for surface treatment applications
• Climate control device (including hot wire anemometer, humidity/temperature sensor, and digital pressure drop gage)
• Portable shop microscope with digital camera attachment
• Digital USB-microscope
• Electrical energy consumption device
• Accessories such smoke tubes and dirt sampling tools

How We Can Help You

A thorough air filter audit of your HVAC Systems is the first step that AAF takes, in order to provide you professional guidance and analysis for cost savings and liability reduction. By conducting this audit, we strive to understand your current state and your complete air filtration needs, applications, and goals for total air quality. This customized air filtration survey costs you nothing and could give you significant benefits by helping you save money, reduce risk, and save time.



Related Case Study

Full Service Contract Helps Automotive Manufacturer Optimise Processes