Reduction of paint defects at a plastic bumper manufacturer
Manufacturing of plastic bumpers
In order to be productive and cost efficient, first-tier car manufacturing suppliers need to increase their production without delays and losses due to product defects. For example, they need to suppress airborne contamination to prevent particle adhesion (microfibers, dust particles, paint particles, etc.) to the paint or prevent static charge which increases the chance of dust-related defects on the product. This is why humidity control is important especially when manufacturing plastic products such as bumpers.
Benefits of AKIMist for painting of bumpers
- Dust suppression
- Non-wetting humidity control
- Better working conditions
- Spot humidification
Common issues bumper manufacturers are facing:
- Static charge generated on the plastic increasing the dust-related defects
- Product defects rate increased due to dust particle adhesion
- Lost in revenue from a high defect rate and repairs
System used for this application
AKIMist® “E” Dry Fog Humidifier
Our AKIMist®“E” spreads a Dry Fog that humidifies indoor environments without wetting due to its tiny droplet size around 7.5 µm. The tiny droplets are ideal for dust suppression their increased surface area allows them to effectively capture and bind with dust particles.
The solution
Our solution help to decrease the paint defects on bumpers by tackling 2 problems at the same time:
- Reduction of particles in the air that cause painting defects (dust particle suppression)
- Prevention of static charge which decrease the number of particles that get stuck in the plastic products, therefore reducing paint defects
Installation
A total of 13 units of AKIMist®“E” were installed between the bumper storage and the paint both: above the conveyors in the unloading storage and the loading area towards the paint line.
- Goal: to reach around 55% relative humidity
Results
Installed with a hygrometer and a control panel, our Dry Fog humidification system can be used 24 hours, 7 days a week, 365 days a year in an automatic mode.
The results often exceed expectations as it helps to reach the level of humidity required without wetting the environment.
As it can be installed for ambient humidification but also spot humification directly above the machines, our solution provided flexibility to the client with the installation.
In this case study, the customer was very satisfied. Therefore, a second installation of AKIMist®“E” got ordered to extend the project.
demo of AKIMist®
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Advantages of AKIMist® against dust-related defects
- Reduction of dust-related painting defects
- Non-wetting solution, no risk of damaging the products or machines
- Flexible installation for spot and ambient humidification with the use of adaptors on the nozzle to fit the factory layout
- Better working conditions
- Reduction of errors cause by ESD
- Energy-efficient
Customer stories: real experiences, genuine satisfaction
Experience the impact of Ikeuchi’s precision spray technology and innovative solutions through the voices of industries worldwide. See how we help businesses excel with custom-made solutions and unparalleled reliability.
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