Protecting our planet is a group project 2003 Earth Award Team Name : TEAM PAINT SHOP Contact no:...

Protecting our planet is a group project 2003 Earth Award

Team Name : TEAM PAINT SHOP

Contact no : 91- 595 - 2357152

Primary Contact : Iqbal KhanMail : ( [email protected] )

TEAM NAME

Nominator information : Abhay DeepMail : ( [email protected] )


PROJECT GOAL

Project Goal :

• Reduction of Natural Resources Usage ( Low Density oil )• Reduction in Power Consumption

Overview:

• XIND Paint shop has conveyorised spray type pre-treatment plant having 7 tank process followed by drying oven .• Wet spray painting is used for both Metallic and plastic ( ABS ) parts .• Baking oven is used for baking of painted parts .• Both Pre-treatment plant & drying oven are heated through close loop Thermic fluid heating system ( Thermax plant ) for which input is liquid LDO ( Low density oil ) .• Air / chemical circulation , air curtain , blower etc. are driven through electricity .


Thermic fluid heating system (Thermax Plant)

INPUT: Electricity for Air curtain , air circulation

& chemical circulation

Degreasing ( 2 tanks )

Phosphating ( 1 tank )

Passivation ( 1 tanks )

Drying oven

BakingOven

Heat

Heat

Rinsing ( 2 tanks )

Rinsing ( 1 tank )

PRE TREATMENT PLANTBAKING OVEN

PROJECT GOAL

Overview cont.

Target : Consumption Reduction

INPUT : Liquid LDO


Plastic parts

Phosphating plant Drying oven

Baking Oven

Painting of parts

• LDO is used to heat drying oven of pre-treatment plant & Baking oven .• Plastic( ABS ) parts are painted and are baked in baking oven .• Metallic parts are phosphated , dryed , painted and then baked

Output

Process : Before

Input LDO+

Electricity

Heat Loss

Heat Loss

HOW WAS THIS ACHIEVED



Plastic parts

Phosphating plant Drying oven

Baking Oven

Painting of parts

Input LDO+

Electricity

• Residual heat of drying oven used to heat Baking oven .• No baking of Plastic parts .

Output

Process : After

Partly heat diverted from drying oven

Residual heat

Heat Loss


Heat transferredthrough mechanical

valve

Baking eliminated by usage of air dry paint hence reduce usage of baking oven



XIND Paint supplier• With help of our paint supplier , various paint samples were developed and tryout were conducted to get desire quality .

XIND Paint shop team• Paint shop team observe that residual heat of Pre-treatment plant used to get waste so they fitted mechanical valve by operating which , heat is getting transferred to baking oven.

• Since initial firing of Oven consume lot of consumable ( LDO ) . Hence paint shop team increased batch size to minimize this consumption.

JAN ‘02• Fitting of mechanical valve to transfer residual heat.• To optimize batch size

MAY-JUNE ‘02• Development of air dry paint . • Trial and tryout on paint and cut-in for production .

RESOURCES

TIMING :

RESOURCES AND TIMING


1.77

0.93

0

0.5

1

1.5

2

2.5

Yr.'2001 Yr.'2002

LDO consumption in Ltr / per m/cYr . 2001 = 1.77 Ltr/ per m/cYr. 2002 = 0.93 Ltr / per m/c

326

215

0

100

200

300

400

Before After

Cost of PU paintEarlier = Rs. 326 per LtrAfter = Rs. 215 per Ltr. (Air Dry)

7.6

5.4

0

2

4

6

8

10

Yr.'2001 Yr.'2002Power consumption ( paint shop only ) in unit / per m/cYr . 2001 = 7.6 unit/ per m/cYr. 2002 = 5.4 unit / per m/c

24

8

0

7

14

21

28

35

Earlier After

Cycle time of PU paint partsEarlier = 24 hrsAfter = 8 hrs.

29 % Reduction

66 % Reduction

47 % Reduction 34 % Reduction

SAVING

TOTAL LDO SAVED IN Yr. 2002 = 7190 LtrTOTAL ELECTRICITY SAVED IN Yr. 2002 = 18.8 kWH

MONETARY SAVING( in Yr. 2002) = $ 4430

RESULTS AND BENEFITS


• ABHAY DEEP• ASHOK SHARMA• AMIR NISHAT• ZAFAR KHAN• BABU KHAN• MUNEER KHAN• MANOJ KR. DAS

TEAM MEMBERS

TEAM MEMBERS

Protecting our planet is a group project 2003 Earth Award Team Name : TEAM PAINT SHOP Contact no:...

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