Case Study
Fiberglass Producer Solves Quality Issue
PanelSpray® MS system increases fiberglass production saving manufacturer over US$140,000 annually
Problem:
A manufacturer needed to improve the spray application of binder fluid on fiberglass prior to it entering a curing oven. The air atomizing nozzles in use didn’t apply the fluid uniformly and frequently applied more than was necessary. Line speed was inconsistent and often required reactionary manual flow rate adjustments, which were imprecise. Not surprisingly, the manufacturer was faced with costly quality problems. In addition, the air atomizing nozzles produced mist that required extra maintenance downtime for equipment cleanup. The high energy costs associated with compressed air was also a concern to the manufacturer.
Solution:
PanelSpray MS System now applies the binder fluid on the fiberglass. Key components of the system include an AutoJet® spray controller and eight PulsaJet® electrically-actuated hydraulic spray nozzles. The nozzles are spaced evenly above the conveyor and provide precise, uniform application of the fluid across the entire width of the fiberglass. Using Precision Spray Control (PSC), the system makes automatic adjustments to flow rate when line speed changes to ensure the proper volume of fluid is applied at all times.
Results:
The use of the PanelSpray MS System has helped the manufacturer resolve its quality problems. In addition, consistent application of the binder on the fiberglass has resulted in significant savings. Decreased binder fluid use saves the manufacturer US$10,000 annually. Labor costs for monitoring the process and maintenance have been reduced by US$118,000 annually. The elimination of compressed air saves US$15,000 annually. The total impact on operating costs, not including the value of the reduction in scrap, is more than US$140,000. The system paid for itself in just three months.
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