Precision gear pumps
Published

Justifying Investments in Automation and Smart Solutions

Corey Sorrento of Carlisle Fluid Technologies discusses the long-term benefits and payoffs for investing in AI-driven technologies for your paint line. 

Corey Sorrento, Carlisle Fluid Technologies

Share

Q: We’re exploring upgrading our plural component systems to incorporate modules with “smart” features but are initially hesitant due to the up-front costs. What are some of the short- and long-term benefits of transitioning to next-gen components, and how can we quantify the ROI to justify the investment?

A: Introducing AI-driven technologies to your paint line yields many immediate and obvious advantages over traditional, user-controlled systems. Many of today’s systems can track inputs, from materials and solvents to compressed air, and optimize their usage to ensure the application meets specifications and any waste in the process is minimized. Higher-end systems can sense environmental conditions such as humidity and temperature and adjust viscosity near the point of atomization to provide the highest degree of precision and transfer efficiency. Time savings from automated purge and load sequences during color changes save labor hours, which equates to reduced downtime and increased production. Machine learning enables systems to anticipate potential issues and suggest preventative action, prolonging the life of components and limiting operation failures. Real-time, closed-loop feedback facilitates the delivery of repeatable and error-free results, bringing consistency to the quality of your finish and reducing the need for rework. Some systems can now monitor energy consumption and VOC emissions, which may suggest adjustments that contribute to corporate sustainability initiatives.

If you have time, please tell us a little more about yourself.

Country

Industries Served

Operations Performed

Welcome to Products Finishing!

Unlimited access to our free premium content requires a little more information from you.

Your email address will be used to communicate with you about Products Finishing subscription offers, related products and services. Refer to our Privacy Policy for more information. Wondering why you’re seeing this? Read more here.

Assigning a dollar value to each of these can help you quickly calculate the overall impact, payback period, and long-term ROI of any proposed capital expenditure. In turn, these savings could directly translate to increased profitability for your business or be passed along to the end customer to give your brand a price-competitive edge in the market.

Q: Are the days of the human in-booth applicator numbered?

A: In recent years, it has been increasingly challenging to recruit, train and retain qualified finishing operators. Experienced professionals may be scarce in some areas or come at a premium. Often paint lines are challenged to maintain production levels with fewer resources, which may translate to higher workloads and more stringent productivity demands. Add the fact that human operators can introduce error into the process — as by nature, we may become distracted, fatigued, or overlook important detail — and the result could prove costly to a finishing operation.

From overuse of resins and solvents to imprecise ratios, wasted time mixing materials, the need for rework or scrap, and the risk of operator injury, the potential for inefficiency is great. Fortunately, the integration of automation in a system adds a level of control by removing the human variable in the equation, providing time, material, and labor savings, added safety in operation, and better consistency in results. Some automated systems feature cloud-based connectivity, allowing users to log in and instantly evaluate performance, manage operations, diagnose and troubleshoot issues, all from a remote location outside the booth. The data can then be exported in real-time or by batch for logging and analysis.

By freeing up these manual tasks, operators can turn their attention to more value-added efforts and focus on monitoring, analyzing and steering the overall process. While automation in in-plant finishing systems will continue to grow, there will always be a place for the operator in an ever-developing and ultimately more collaborative role alongside the supporting technology.

About the Author

Corey Sorrento headshot
Photo Credit: Carlisle Fluid Technologies

Corey Sorrento

Corey Sorrento is the global product manager for the mix, meter and flow as well as cure and convey product lines for Carlisle Fluid Technologies. Visit carlisleft.com.

Precision gear pumps
ENGINEERED PAINT BOOTHS & FINISHING SOLUTIONS
Your Best Finish Starts With Us!
Heatmax Heaters ad with immersion heaters
New Acid-Free Bright Nickel Process
Gardner Intelligence
Filtration Systems
find masking products online

Related Content

Liquid Coating

Surface Prep Solution for Rusted Rebar in Concrete

Julie Holmquist of Cortec Corporation discusses passivating corrosion on rebar and other reinforcing metals.

Read More
Ask The Expert

How to Choose Between Sulfate and Chloride-Based Trivalent Chromium

There are several factors to consider when choosing between sulfate and chloride-based baths for trivalent chromium plating. Mark Schario of Columbia Chemical discusses the differences and what platers should keep in mind when evaluating options.

Read More
Electroplating

Troubleshooting Alkaline Zinc

One of the most common problems that can arise when plating with alkaline zinc is an imbalance of brightener in the solution. In this helpful Ask the Expert article, Chad Murphy of Columbia Chemical discusses how different zinc metal concentrations and brightener concentrations can impact efficiency.

Read More
Ask The Expert

Liquid Chrome Vs. Chromic Acid Flake

Contemplating how to continue offering chromic acid services in an increasingly stringent regulatory world? Liquid chrome products may be the solution you’re looking for.

Read More

Read Next

Industry 4.0

Digitizing Your Job Shop for Increased Production and Profitability

Dean Halonen of ERP software provider Steelhead Technologies discusses how digitizing your metal finishing job shops can help you achieve more production throughput and improve profitability.

Read More
Industry 4.0

Episode 32: An Interview with Bobby Haggard, TrinSoft LLC

A wide variety of ERP systems are on the market ranging from off-the-shelf solutions to custom programs. What should finishing operations keep in mind when exploring a new ERP solution?

Read More
Liquid Coating

When to Introduce Automation Into Your Finishing System

Looking to increase productivity for your liquid coating operation? John Owed of Carlisle Fluid Technologies provides examples of how automation can help improve quality and efficiency for paint spray equipment.

Read More
Industrial Finishing Equipment