Cost savings in paint usage and maintenance requirements
September 2013 – Dürr’s Application Technology continues to build on its success with EcoBell2 upgrades on competitor equipment by adding another launch this past summer. This latest successful upgrade was at the Chrysler Warren Truck Assembly Plant (WTAP). This technology uses the EcoBell2 atomizer with a bell cup that was specially designed for the application of metallic paints: the "M" cup.
A total of 16 EcoBell2 M atomizers replaced existing guns on competitor robots at WTAP. The installation, commissioning, and launch occurred during Chrysler’s scheduled July shutdown. Dürr was on-time for all benchmarks, so Chrysler was able to resume full production as scheduled.
The guns that the EcoBell2 M technology replaced were used with both metallic and solid paints for both exterior and interior box applications. In order to give the metallic paint finish the desired sparkle and color match, each gun uses more paint than an EcoBell2 M to obtain the same quality. Because each gun also has a lower Transfer Efficiency (TE) than an EcoBell2 M, there is a lot of overspray—this causes wasted paint and higher cleaning costs. The high TE of the EcoBell2 means that there are cost savings in both paint usage and with maintenance requirements. Less cleaning labor and cleaning solvent is used within the booth and there is less accrued contamination of components. Guns also require a high air pressure and fast air speeds—making them much more expensive to operate than the EcoBell2 M.
The EcoBell2 M process provides additional cost savings due to the improvement in quality and first-time-through rates (FTT). And the environmental factor cannot be ignored. Less paint is used and less paint is wasted. This results in less solvent being used, less paint coagulation, and lower disposal costs.
Dürr USA’s latest upgrade at Chrysler Warren Truck Assembly Plant (MI) has produced exceptional results in just one month of operation: 1.0 point improvement in all colors (according to Chrysler’s color measuring system), 30% paint savings in the second pass of the basecoat, virtual elimination of color carryover, substantial reduction in sludge and cleaning costs, and a marked reduction in defects. This is yet another in a series of upgrades that are occurring at Chrysler plants in North America. Dürr’s Application Technology has single-sourced this type of applicator upgrade at Chrysler Brampton, Chrysler Toledo North, and two previous upgrades at Chrysler Warren Truck. Another project is planned for Chrysler Brampton during the Christmas 2013 shutdown.