1. Minimizing Paint Waste

2. Environmental & Health Concerns Hazardous waste Hazardous waste Mixed coatings and solvent Mixed coatings and solvent Toxic, flammable Toxic, flammable Air emissions Air emissions Toxic constituents Toxic constituents Toluene, xylene, MEK Toluene, xylene, MEK Smog forming VOCs Smog forming VOCs

3. Paint Waste Sources Mixing room Mixing room Overestimate Overestimate Overmix Overmix Overspray Overspray Technique Technique Equipment Equipment Re-work jobs Re-work jobs Color not matched Color not matched Dust and dirt Dust and dirt Finish quality Finish quality

4. Manage Inventory Just-in-time ordering Just-in-time ordering First-in, first-out First-in, first-out Keep containers closed Keep containers closed Mixing banks Mixing banks

5. Color Matching Mix in small amounts Mix in small amounts Start with 8 oz. or less Start with 8 oz. or less Spray out on test panels Spray out on test panels View and compare in natural light View and compare in natural light Colorimeter or spectrophotometer Colorimeter or spectrophotometer Expertise of other painters Expertise of other painters Color library of spray-outs Color library of spray-outs Record color mix information Record color mix information

6. Paint Measurement Computerized mixing system Computerized mixing system Tracks product use and VOCs Tracks product use and VOCs Reports for air district Reports for air district Automated paint dispenser Automated paint dispenser Minimizes over-pours Minimizes over-pours Minimize paint transfers Minimize paint transfers

7. Track and Troubleshoot Record each step Record each step Estimated amount Estimated amount Actual amount mixed Actual amount mixed Left over Left over Compare estimated and actual paint used to refine estimating Compare estimated and actual paint used to refine estimating Compare paint orders with workload Compare paint orders with workload Work with painter to resolve Work with painter to resolve

8. Paint left over Mix into ground coat Mix into ground coat Cover hard to hide colors Cover hard to hide colors Under dark color coat Under dark color coat Will it change regulated VOC content? Will it change regulated VOC content? Check with air district Check with air district Door interiors, edging, jambing Door interiors, edging, jambing Save popular colors for later use Save popular colors for later use

9. Calibrated Liners

11. Advantages Mix in cup liner Mix in cup liner Mix more than one batch at a time Mix more than one batch at a time Increases application efficiency and reduces paint overspray Increases application efficiency and reduces paint overspray Cover and save mixed paint for a limited time Cover and save mixed paint for a limited time Reduces cleaning solvent and waste Reduces cleaning solvent and waste Do not need to clean paint pot Do not need to clean paint pot Reduces labor Reduces labor Increased production Increased production

12. Job Planning Primer and clear coat back-to-back Primer and clear coat back-to-back Tintable primer systems Tintable primer systems Schedule waterborne primer application to allow drying time Schedule waterborne primer application to allow drying time Remove part before painting Remove part before painting No masking needed No masking needed Reduces overspray Reduces overspray Streamlines process Streamlines process

13. Painting Spray efficiency Spray efficiency Finish quality Finish quality Transfer efficiency (TE) Transfer efficiency (TE) How much paint gets on the surface How much paint gets on the surface Build efficiency (BE) Build efficiency (BE) Amount of build (mils) applied on surface compared to amount sprayed Amount of build (mils) applied on surface compared to amount sprayed Many variables effect spray efficiency Many variables effect spray efficiency Technique Technique Equipment and settings Equipment and settings Correct use of product Correct use of product Part geometry Part geometry

14. Improve Spray Efficiency Poor technique Wastes paint Wastes paint More clean-up More clean-up Painter labor Painter labor Paint technician training Paint technician training Technology Technology Higher efficiency spray guns Higher efficiency spray guns Targeting device for training and application Targeting device for training and application

15. Painter Training Painters learn to apply paint more efficiently Hands-on training Hands-on training Students practice proper technique Students practice proper technique Techniques for specific coatings Techniques for specific coatings I-CAR training centers I-CAR training centers Paint manufacturer training Paint manufacturer training Community college automotive programs Community college automotive programs IWRC STAR ® Program,Spray Technique Analysis and Research IWRC STAR ® Program,Spray Technique Analysis and Research http://www.iwrc.org/STAR/STARschools.htm http://www.iwrc.org/STAR/STARschools.htm LA Trade Technical College LA Trade Technical College IWRC STAR training for defense IWRC STAR training for defense http://www.star4d.org http://www.star4d.org ARB P2 web page- auto refinishing ARB P2 web page- auto refinishing http://www.arb.ca.gov/coatings/p2/overview.htm http://www.arb.ca.gov/coatings/p2/overview.htm http://www.arb.ca.gov/coatings/p2/overview.htm

16. Technology LaserPaint™ LaserPaint™ Application technique and targeting tool Application technique and targeting tool Allows painter to: Allows painter to: Maintain correct angle and distance for consistent coverage Maintain correct angle and distance for consistent coverage Optimize overlap Optimize overlap Reduce overspray Reduce overspray Developed by Iowa Waste Reduction Center (IWRC) Developed by Iowa Waste Reduction Center (IWRC) http://www.laserpaint.us http://www.laserpaint.us http://www.laserpaint.us

17. Cost: $300 includes mounting bracket and training CD LaserPaint tool developed by IWRC http://www.laserpaint.us http://www.laserpaint.us

18. Environmental Technology Verification LaserPaint LaserPaint ARB certified performance claim ARB certified performance claim 15% volume reduction average 15% volume reduction average USEPA environmental technology verification (ETV) May 2000 http://www.epa.gov/etv/verifications/vcenter6- 5.html USEPA environmental technology verification (ETV) May 2000 http://www.epa.gov/etv/verifications/vcenter6- 5.htmlhttp://www.epa.gov/etv/verifications/vcenter6- 5.htmlhttp://www.epa.gov/etv/verifications/vcenter6- 5.html High TE Spray Equipment High TE Spray Equipment ETV report http://www.epa.gov/etv/verifications/vcenter6- 16.html ETV report http://www.epa.gov/etv/verifications/vcenter6- 16.htmlhttp://www.epa.gov/etv/verifications/vcenter6- 16.htmlhttp://www.epa.gov/etv/verifications/vcenter6- 16.html

19. Painter Training Virtual Paint- computer simulated training Virtual Paint- computer simulated training http://www.virtualpaint.us/ http://www.virtualpaint.us/

20. Virtual Paint Painters learn proper technique Painters learn proper technique Reduces waste and costs Reduces waste and costs Advantages Advantages No paint waste- booth and filters, equipment, clothing No paint waste- booth and filters, equipment, clothing No air emissions No air emissions No clean up waste No clean up waste Disadvantages Disadvantages High cost of technology High cost of technology Availability Availability

21. Paint Spray Booths

22. Functions of Spray Booths Facilitates cleaner paint jobs Facilitates cleaner paint jobs Contains overspray Contains overspray Collects waste Collects waste Provides clean air during paint operations Provides clean air during paint operations Provides well lit area, devoid of dust Provides well lit area, devoid of dust Protects worker’s health Protects worker’s health Confines harmful emissions in one area Confines harmful emissions in one area Prevents workers outside of booth from inhaling solvent emissions and paint particles Prevents workers outside of booth from inhaling solvent emissions and paint particles Workers painting within booth should wear personal protective equipment Workers painting within booth should wear personal protective equipment Monetary savings Monetary savings Reduces operation costs Reduces operation costs Lowers labor costs Lowers labor costs Reduces material costs Reduces material costs Filters paint particles from air before exhausting it into the atmosphere Filters paint particles from air before exhausting it into the atmosphere

23. Types of Paint Spray Booths Spray booths provide uniform airflow Spray booths provide uniform airflow Two most common types of spray booths Two most common types of spray booths (1) Cross draft spray booth (2) Down draft spray booth

24. Cross Draft Spray Booth Air is drawn in across filters on the front end of the room into filters located on the opposite end of the room. Air is drawn in across filters on the front end of the room into filters located on the opposite end of the room.

25. Down Draft Spray Booths Air is pulled down through inlet filters on the ceiling into exhaust filters located on the floor.

26. Combination Drying Booths Two distinct operating cycles Two distinct operating cycles (1) Painting (2) Heated drying cycle Decreases curing time Decreases curing time High productivity due to fast processing time High productivity due to fast processing time Allows for good finish quality and reduces re-working Allows for good finish quality and reduces re-working Conserves energy Conserves energy Uses recirculating airflow Uses recirculating airflow More cost effective over lifespan of equipment More cost effective over lifespan of equipment Reduces costs Reduces costs Operation and maintenance Operation and maintenance Labor Labor

27. Spray Booth Considerations Serviceability Serviceability Select from a vendor that offers maintenance, support, and warranty Select from a vendor that offers maintenance, support, and warranty Choose a vendor that is accessible to reduce downtime when replacement parts and/or repairs are needed Choose a vendor that is accessible to reduce downtime when replacement parts and/or repairs are needed Lighting Lighting Fluorescent Fluorescent Runs cooler Runs cooler Consumes less energy Consumes less energy High-Intensity Discharge (HID) High-Intensity Discharge (HID) Delivers more lighting per lamp Delivers more lighting per lamp Requires longer warm-up time Requires longer warm-up time Filter Filter Most important component of a spray booth, must be capable of holding and capturing all dirt, overspray, and solvent Most important component of a spray booth, must be capable of holding and capturing all dirt, overspray, and solvent Prevents paint build-up on fans, exhaust, and release of paint particulates into the environment Prevents paint build-up on fans, exhaust, and release of paint particulates into the environment

28. Paint Spray Booth Interior – Down Draft Spray Booth Fluorescent Lighting Polyethylene Sheeting/ Masking Cling Film Grates Ceiling Air Inlet, filters above inlets Filters beneath grates

29. Air Intake and Filters

30. Maintain Spray Booth and Components Produces cleaner paint jobs, reduces waste, and protects worker’s health Produces cleaner paint jobs, reduces waste, and protects worker’s health Results in lower labor costs, reduces operation costs, and reduces material costs Results in lower labor costs, reduces operation costs, and reduces material costs Develop a routine maintenance schedule that includes: Develop a routine maintenance schedule that includes: Changing filters Changing filters Masking off booth surface and equipment Masking off booth surface and equipment Checking paint buildup on fans Checking paint buildup on fans Overall good housekeeping Overall good housekeeping

31. Maintain Spray Booth Manometer- check routinely for optimum air flow Keep booth clean Remove dust and debris

32. Paint Waste Reduction Waste reduction equates to cost savings for shops Waste reduction equates to cost savings for shops Employee incentives Employee incentives Ask for their ideas Ask for their ideas Share cost savings of significant waste reduction with workers Share cost savings of significant waste reduction with workers Allow time and incentives for training refreshers Allow time and incentives for training refreshers