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Louisville, KY -- PPG Architectural Finishes, a latex paint and stain manufacturer, knew its filling operation was overly complicated, noisy, and required far too much operator attention. More importantly, PPG experienced an unacceptable percentage of product loss in the filtering process.
An air operated diaphragm pump at the base of a blend tank pumped product onto a large, open, vibrating screen. Product exiting the vibrating screen fed into an accumulating vessel, where another pump transferred product through a polishing filter into a rotary drum-filling machine. With the two pumps, vibrating screen, and open-air vessel, the system was complex, noisy, and wasteful.
To stay competitive in the tough, low margin paint industry, Doug Story, Plant Engineer at the Louisville site, aimed to streamline the company’s filling operation. His goals: to produce as much finished product as possible, using the least wasteful, most environmentally friendly methods available.
In consultation with RPA Process, PPG replaced their vibrating screen, accumulating vessel, and diaphragm pump with a DCF-800, mechanically-cleaned filter. Removing the vibrating screen eliminated the need for the accumulating vessel, associated piping and controls, as well as the second diaphragm and its compressed air components and controls.
The DCF filter has virtually eliminated operator involvement in the operation, and removing the vibrating screen and second diaphragm pump has dramatically reduced noise levels. The DCF filter purges residual paint and debris into the plant recycling system, where the solids are separated and the paint is reused.
According to Doug Story, there has been a significant reduction in product waste. "Post installation cost for the first year was under $10 (USD)," says Story. "Payback was achieved in four months, and this analysis does not include the savings generated in utility costs for the vibrating screen, its maintenance, or additional operator time. The DCF filter has contributed to our paint and stain production efficiency, and exceeded the objectives set at the beginning of the project. It also provides our workers with a quieter, more environmentally friendly workplace."
For more information on self-cleaning filter technology, contact:
RPA Process Technologies, Inc.
151 Shaver Road
Portage, MI 49024
Telephone: 866-867-2893 toll free
Fax 269-323-2403
Web site: www.rpaprocess.com.
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