1. 1 STAR STAR  Increased Profits Through Efficient Spraying Ken Grimm Pacific Northwest Pollution Prevention Resource Center (PPRC) PPRC Spray Technique Applied Research

2. 2 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research What is PPRC? We are the leading regional non-profit that provides practical, on-the-ground technical assistance to businesses, public agencies and non-profits that are seeking to conserve resources and improve economic performance.

3. 3 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research What is PPRC? http://www.pprc.org http://www.p2rx.org One of eight regional centers encompassing the entire United States

4. 4 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research Our Goal Today  Get familiar with new surface coating requirements Area Source Rule Subpart HHHHHH  Get familiar with the elements of the STAR manual spray efficiency program  Meet the NESHAP training requirements

5.  All Painters complete training in techniques to minimize paint overspray  No spray gun cleaning by spraying solvent that creates an atomizing mist  Routine spray booth and filter maintenance  High efficiency spray guns  Documentation of compliance 5 PPRC STAR STAR  Increased Profits Through Efficient Spraying NESHAP Standard Requires: Spray Technique Applied Research

6.  Initial training – valid for a period of 5 years  Refresher training at least once every 5 years  Training completed by 3 years from NESHAP date (1/10/2011) or 180 days after hiring. 6 PPRC STAR STAR  Increased Profits Through Efficient Spraying NESHAP Standard Requires: Spray Technique Applied Research

7. Requires NESHAP Standard Requires:  Initial and Refresher training must address spray gun equipment selection, set-up and operation, including:  Measuring coating viscosity  Selecting proper fluid tip and nozzle  Achieving proper spray pattern  Achieving proper air pressure and volume  Achieving proper fluid delivery rate 7 PPRC STAR STAR  Increased Profits Through Efficient Spraying Spray Technique Applied Research

8. NESHAP Standard Requires:  Improve transfer efficiency and minimize coating usage and overspray by:  Maintaining correct spray gun distance and angle  Using proper banding and overlap  Reducing lead and lag 8 PPRC STAR STAR  Increased Profits Through Efficient Spraying Spray Technique Applied Research

9. 9 Why Address Collision Repair?  Aggregated affect: The following table lists the toxic weighted (cancer risk) emissions of various sectors in the United States. Figures are tons per year.  Source: EPA area source category list – 21 sectors. PPRC STAR STAR  Increased Profits Through Efficient Spraying Spray Technique Applied Research

10. Why Address Collision Repair? 10 Agricultural Chemicals & Pesticide Mfg 312 Pharmaceutical Production Paint & Allied Products Industrial Boilers Flexible Polyurethane Foam Operations Autobody Refinishing PPRC STAR STAR  Increased Profits Through Efficient Spraying Spray Technique Applied Research

11. 11 Why Address Collision Repair? Agricultural Chemicals & Pesticide Mfg 312 Pharmaceutical Production 523 Paint & Allied Products Industrial Boilers Flexible Polyurethane Foam Operations Autobody Refinishing PPRC STAR STAR  Increased Profits Through Efficient Spraying Spray Technique Applied Research

12. 12 Why Address Collision Repair? Agricultural Chemicals & Pesticide Mfg 312 Pharmaceutical Production 523 Paint & Allied Products 2,393 Industrial Boilers Flexible Polyurethane Foam Operations Autobody Refinishing PPRC STAR STAR  Increased Profits Through Efficient Spraying Spray Technique Applied Research

13. 13 Why Address Collision Repair? Agricultural Chemicals & Pesticide Mfg 312 Pharmaceutical Production 523 Paint & Allied Products 2,393 Industrial Boilers 2,582 Flexible Polyurethane Foam Operations Autobody Refinishing PPRC STAR STAR  Increased Profits Through Efficient Spraying Spray Technique Applied Research

14. 14 Why Address Collision Repair? Agricultural Chemicals & Pesticide Mfg 312 Pharmaceutical Production 523 Paint & Allied Products 2,393 Industrial Boilers 2,582 Flexible Polyurethane Foam Operations 5,289 Surface Coating PPRC STAR STAR  Increased Profits Through Efficient Spraying Spray Technique Applied Research

15. 15 Why Address Collision Repair? Agricultural Chemicals & Pesticide Mfg 312 Pharmaceutical Production 523 Paint & Allied Products 2,393 Industrial Boilers 2,582 Flexible Polyurethane Foam Operations 5,289 Surface Coating 45,456 PPRC STAR STAR  Increased Profits Through Efficient Spraying Spray Technique Applied Research

16. NESHAP Standard Requires Paint Booths NESHAP Standard Requires: Paint Booths  Spray applied coatings must be done in a booth or a prep station  Large enough to hold complete vehicle:  Four complete side walls or curtains  Complete roof  Subassemblies or parts  Three complete side walls or curtains  Complete roof 16 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research

17. NESHAP Standard Requires: Filter Efficiency Requirements  Filters now required to be 98% efficient.  Must have certification that filters meet this requirement  Paint Arrestance Filter Test Report 17 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research

18. 18 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research

19. Methylene Chloride Paint Stripper NESHAP Standard Includes: Methylene Chloride Paint Stripper  Investigate alternatives.  Optimize application conditions.  Practice proper storage and disposal  Maintain records of annual usage  Develop and implement MeCl minimization plan if usage ≥ 1 ton. 19 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research “must implement management practices that reduce emissions of MeCl by minimizing evaporative loss.”

20.  The STAR Training Program started in 1994  Applied research project funded by the Small Business Administration and the EPA  Project’s goal: determine the most cost effective and practical approach to improving manual spray efficiency in the automotive refinishing industry.  The study resulted in a focus on improving spray efficiency through technician training. 20 STAR Program History PPRC STAR STAR  Increased Profits Through Efficient Spraying Spray Technique Applied Research

21. 21 STAR STAR  Increased Profits Through Efficient Spraying PPRC Variables Affecting Spray Efficiency (Uncontrollable Variables)  Air Supply System  Booth Conditions  Air flow rate and direction  Relative humidity  Operation space  Lighting Spray Technique Applied Research

22. 22 STAR STAR  Increased Profits Through Efficient Spraying PPRC Variables Affecting Spray Efficiency (Uncontrollable Variables)  Size and geometry of part  Coating type and color  Coating mil thickness requirements  Finish quality requirements Spray Technique Applied Research

23. 23 STAR STAR  Increased Profits Through Efficient Spraying PPRC Variables Affecting Spray Efficiency (Controllable Variables)  Mixture Content  Booth Operating Temperature  Spray Equipment Type  Equipment Maintenance Practices  Gun Setup Spray Technique Applied Research

24. 24 STAR STAR  Increased Profits Through Efficient Spraying PPRC Variables Affecting Spray Efficiency (Controllable Variables)  Spray Distance  Spray Angle  Spray Techniques  Advanced Techniques  Plan Of Attack Spray Technique Applied Research

25. 25 STAR STAR  Increased Profits Through Efficient Spraying What Is Transfer Efficiency? Transfer efficiency is the measurement of how much paint sprayed is actually applied to the part being painted. PPRC Spray Technique Applied Research

26. 26 STAR STAR  Increased Profits Through Efficient Spraying Transfer Efficiency = Mass of solids deposited Mass of solids sprayed Or Transfer Efficiency = Volume of solids deposited Volume of solids sprayed PPRC How is Transfer Efficiency Measured? Spray Technique Applied Research

27. 27 STAR STAR  Increased Profits Through Efficient Spraying PPRC Why Is Transfer Efficiency Important?  Material savings: Increased transfer efficiency reduces material usage.  Health impact: Toxins, solvents, and other ingredients can cause adverse health impacts. Spray Technique Applied Research

28. Health Impacts 28 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research

29. 29 STAR STAR  Increased Profits Through Efficient Spraying PPRC Why Is Transfer Efficiency Important?  Environmental impacts: Volatile organic compounds (VOC’s) are air pollutants which produce ozone (smog).  Reduced environmental liabilities: Reduction in the pollutants emitted will reduce liability and may reduce regulatory burden. Spray Technique Applied Research

30. 30 STAR STAR  Increased Profits Through Efficient Spraying Why Is Transfer Efficiency Important?  Even good, experienced painters frequently have a transfer efficiency of 50 % or less.  Even a 10% improvement in transfer efficiency can have dramatic affects on costs and air emissions. PPRC Spray Technique Applied Research

31. 31 STAR STAR  Increased Profits Through Efficient Spraying 40% Transfer Efficiency PPRC Spray Technique Applied Research Why Is Transfer Efficiency Important?

32. 32 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research Why Is Transfer Efficiency Important?

33. 33 STAR STAR  Increased Profits Through Efficient Spraying PPRC Transfer Efficiency Shortcomings Transfer efficiency is not the best means of measuring the efficiency of a paint system because it does not consider the build of the coating applied. To account for build difference, build efficiency is used. Spray Technique Applied Research

34. 34 STAR STAR  Increased Profits Through Efficient Spraying PPRC What Is Build Efficiency? Build Efficiency = Avg. Mils Applied x Area Sprayed Avg. Mils Applied x Area Sprayed Mass of Paint Sprayed Mass of Paint SprayedOr The amount of build you get out of the paint you spray  Consistency  Consistency is the key to build efficiency. Spray Technique Applied Research

35. STAR  Spray Techniques  Spray gun distance to part  Perpendicular to surface  Spray angle  Consistent 50% overlap  Banding and edging  Reduce lead and lag 35 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research

36. 36 STAR STAR  Increased Profits Through Efficient Spraying PPRC Mixture Content  Choice of thinner/reducer: Choose the product recommended by the manufacturer for the material being sprayed and spray conditions.  Mixing ratio: Mix according to the manufacturer’s requirements. Do not over reduce. Occasionally take Zahn readings to ensure proper viscosity. Spray Technique Applied Research

37. 37 STAR STAR  Increased Profits Through Efficient Spraying PPRC  Choice of equipment should be based on the coating type.  Choose equipment that will effectively atomize the coating at a low PSI setting. Spray Equipment Type Spray Technique Applied Research

38. 38 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Equipment Maintenance Practices Guns must be cleaned and maintained regularly to ensure optimum atomization and spray pattern. Spray Technique Applied Research

39. 39 STAR STAR  increased Profits Through Efficient Spraying PPRC Gun Setup Fan Setting.  Fan setting should be appropriate for the geometry of the part being sprayed. Spray Technique Applied Research

40. 40 STAR STAR  Increased Profits Through Efficient Spraying PPRC Gun Pattern  Know the shape and size of your spray pattern at full and partial trigger. Spray Technique Applied Research Gun Setup

41. 41 STAR STAR  Increased Profits Through Efficient Spraying PPRC Use the spray pattern to your advantage. Spray Technique Applied Research Gun Setup

42. 42 STAR STAR  Increased Profits Through Efficient Spraying PPRC Air Pressure Settings  Air pressure should be set at the lowest setting that allows adequate atomization. Gun Setup Spray Technique Applied Research

43. 43 STAR STAR  Increased Profits Through Efficient Spraying PPRC Gun Setup Spray Technique Applied Research Air pressure too high =  Low transfer efficiency  Wasted material  Excessive overspray  Low film build  Poor finish quality

44. 44 STAR STAR  Increased Profits Through Efficient Spraying PPRC Gun Setup Spray Technique Applied Research Air pressure too low =  “Heavy-centered spray pattern  Excessive film build  Orange peel  Runs / sags

45. 45 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Distance Gun distance should follow the manufacturer’s recommendation for both gun and product being applied. Spray Technique Applied Research

46. 46 STAR STAR  Increased Profits Through Efficient Spraying PPRC Fluid setting  High fluid settings require high air pressure to properly atomize the coating.  Keep fluid setting as low as possible while still maintaining comfortable gun speed. Gun Setup Spray Technique Applied Research

47. 47 STAR STAR  Increased Profits Through Efficient Spraying PPRC Fluid delivery too high =  Runs or sags  Solvent popping  Excessive film build  Poor atomization Gun Setup Spray Technique Applied Research

48. 48 STAR STAR  Increased Profits Through Efficient Spraying PPRC Fluid delivery too low  Dry spray  Low film build  Multiple coats required  Lower productivity Gun Setup Spray Technique Applied Research

49. 49 STAR STAR  Increased Profits Through Efficient Spraying PPRC Keep the distance consistant. Spray Distance Spray Technique Applied Research

50. 50 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Distance Spray Technique Applied Research

51. 51 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Distance Do not arc the gun. Spray Technique Applied Research

52. 52 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research Spray Distance

53. 53 STAR STAR  Increased Profits Through Efficient Spraying PPRC Yaw (wrist moving left or right) Spray Angles Spray Technique Applied Research

54. Spray Angle - Yaw 54 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research

55. 55 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Angle - Yaw Spray Technique Applied Research

56. 56 STAR STAR  Increased Profits Through Efficient Spraying PPRC Pitch (wrist turned up or down) Spray Angles Spray Technique Applied Research

57. 57 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Angles - Pitch Spray Technique Applied Research

58. 58 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Angle: Pitch Spray Technique Applied Research

59. 59 STAR STAR  Increased Profits Through Efficient Spraying PPRC Rotation (wrist turned either clockwise or counter clockwise) Spray Angle - Rotation Spray Technique Applied Research

60. 60 STAR STAR  Increased Profits Through Efficient Spraying Spray Angle - Rotation PPRC Spray Technique Applied Research

61. 61 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Angle - Rotation Spray Technique Applied Research

62. 62 STAR STAR  Increased Profits Through Efficient Spraying PPRC Lead and Lag Distance.  Lead is the distance between the point where the gun is triggered and the point where the gun pattern hits the part.  Lag is the distance between the point where the pattern leaves the part and the point where the gun is un-triggered.  Both should be kept to a minimum. Spray Techniques Spray Technique Applied Research

63. 63 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research Conventional Lead and Lag

64. 64 STAR STAR  Increased Profits Through Efficient Spraying PPRC Conventional Lead and Lag Spray Technique Applied Research

65. 65 STAR STAR  Increased Profits Through Efficient Spraying PPRC Improved Lead and Lag Spray Technique Applied Research

66. 66 STAR STAR  Increased Profits Through Efficient Spraying PPRC Conventional banding sprays half the pattern off the edge. Advanced Techniques Spray Technique Applied Research

67. 67 STAR STAR  Increased Profits Through Efficient Spraying PPRC Conventional Banding Spray Technique Applied Research

68. 68 STAR STAR  Increased Profits Through Efficient Spraying PPRC Full fan banding.  Keep as much spray pattern as possible on the part. Advanced Techniques Spray Technique Applied Research

69. 69 STAR STAR  Increased Profits Through Efficient Spraying PPRC Full Fan Banding Spray Technique Applied Research

70. 70 STAR STAR  Increased Profits Through Efficient Spraying PPRC Advanced Techniques- Hood Banding Spray Technique Applied Research

71. 71 STAR STAR  Increased Profits Through Efficient Spraying PPRC Advanced Techniques- Hood Banding Spray Technique Applied Research

72. 72 STAR STAR  Increased Profits Through Efficient Spraying PPRC  Devise a spray sequence that will allow you to paint the part without applying multiple coats to any one area during any one pass.  Look for ways to use partial triggering, edging and full fan banding when appropriate.  Always keep as much of the spray pattern on the part as possible. Plan of Attack Spray Technique Applied Research

73. 73 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research

74. 74 STAR STAR  Increased Profits Through Efficient Spraying 74 PPRC Spray Technique Applied Research

75. 75 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research

76. 76 STAR STAR  Increased Profits Through Efficient Spraying PPRC Benefit of Efficiency Improvement If Joe, a technician of 10 years, enters the STAR training program spraying at 30% transfer efficiency and exceeding his target build by 60%, he would spend $20,590 on paint material and arrestors in an average year. Spray Technique Applied Research

77. 77 STAR STAR  Increased Profits Through Efficient Spraying PPRC Benefit of Efficiency Improvement If, after completing the STAR training program, he increases his transfer efficiency by 50% and exceeds his target build by only 30%, he will spend only $11,949 in a year’s time.  This is a saving of $8,641 every year! Spray Technique Applied Research

78. 78 STAR STAR  Increased Profits Through Efficient Spraying PPRC Mil Thickness Gauges Zahn Cup Spray Technique Applied Research

79. 79 STAR STAR  Increased Profits Through Efficient Spraying PPRC LaserPaint Training Device http://www.iwrc.org/Laser/# Spray Technique Applied Research

80. 80 STAR STAR  Increased Profits Through Efficient Spraying PPRC Spray Technique Applied Research 3M 3M Akzo Nobel Akzo Nobel DuPont Performance Coatings DuPont Performance Coatings Mattos Mattos BASF BASF Alabama Collision Repairers Industry Assoc. Alabama Collision Repairers Industry Assoc. Inter-Industry Conference Auto Collision Repair (I-CAR) Inter-Industry Conference Auto Collision Repair (I-CAR) Coordinating Committee for Automotive Repair (CCAR) Coordinating Committee for Automotive Repair (CCAR) Iowa Waste Reduction Center’s STAR program Iowa Waste Reduction Center’s STAR program National Automotive Technicians Educational Foundation (NATEF) National Automotive Technicians Educational Foundation (NATEF) National Automotive Dealer’s Assoc. (NADA) National Automotive Dealer’s Assoc. (NADA) Clean Air Partners Clean Air Partners PPG Industries – Seattle PPG Industries – Seattle Pacific Northwest Pollution Prevention Resource Center Pacific Northwest Pollution Prevention Resource Center Clean Air Minnesota Clean Air Minnesota Rochester Green Business Network Rochester Green Business Network

81. 81 STAR STAR  Increased Profits Through Efficient Spraying Waterborne Webinar PPRC Spray Technique Applied Research

82. 82 STAR STAR  Increased Profits Through Efficient Spraying Waterborne Webinar PPRC Spray Technique Applied Research

83. 83 STAR STAR  Increased Profits Through Efficient Spraying Contact Info  Ken Grimm  kgrimm@pprc.org kgrimm@pprc.org  206-352-2050 PPRC Spray Technique Applied Research

84. 84 STAR STAR  Increased Profits Through Efficient Spraying Recordkeeping (keep on file)  Notifications submitted to EPA.  Painter training certifications.  Spray booth filter efficiency documentation.  MeCl content information such as MSDS.  Annual usage of MeCl for paint stripping  Viscosity checks. PPRC Spray Technique Applied Research  Spray gun transfer efficiency.  Written MeCl minimization plan.  Exemption notice from EPA  Deviation and corrective action documentation. Recordkeeping (if needed)