New Spray System Reduced Adhesive Usage by 60%, While Nearly Doubling Capacity . . . Maintenance Reduced from Every Few Minutes to Once a Shift
 Latex-Based Adhesive Caused Numerous Problems on Carpet Backing Material
This company applies a latex-based adhesive to both sides of a carpet backing material before it is shipped to hardware and home center stores nationwide. Homeowners use the product to apply an area rug over existing carpeting. If the factory applies too much adhesive to the backing material, it can soil the homeowner's carpeting leading to customer complaints. Too little adhesive and the area rug won't adhere properly.
PROBLEM: The company previously used Spraying Systems Co.'s UniJet® spray nozzles. However, the latex-based adhesive was difficult to spray, causing the spray nozzles to plug once every 5 to 6 minutes. To compensate for the frequent nozzle clogging, the system was designed with three nozzles providing triple coverage for adequate coating. However, the adhesive is expensive, so overspraying was not an adequate long-term solution.
SOLUTION: With the introduction of the new VAU variable spray nozzle, the Spraying Systems Co. sales engineer knew the problem could be solved. He not only recommended the spray nozzles, but also assisted with the design of the spray system and the spray booth, and with specifying the pump, controls and all accessories. He even assisted with startup and tuning of the nozzles to optimize spray performance.
The new spray system has improved production in a number of ways. First, because the VAU variable spray nozzles allow for independent adjustment of the atomizing air, fan air and liquid flow, the capacity, drop size and spray pattern can be fine-tuned for precise coverage. Now, rather than soaking the backing fiber, the VAU variable spray nozzles apply a fine mist to the backing fibers. Secondly, since the adhesive is now applied so evenly, usage has dropped from four 500 gallon (1892.5 liter) totes per day (at a cost of $1,200 (US Dollars) per tote) to 1-½ totes every day. The VAU variable spray nozzle's built-in orifice clean-out needle is automatically activated between each spray cycle. Instead of cleaning nozzles every 5 to 6 minutes, nozzle maintenance is now conducted routinely at the end of each shift. And the employees who were responsible for nozzle maintenance have been reassigned to a new custom cutting line.
The system paid for itself in just three months due to adhesive cost savings and the reduction in maintenance time.
The payback period doesn't include the benefits from increased capacity. Less adhesive application requires less drying time in the ovens, allowing line speed to increase from 30' (9.1 m) per minute to 55' (16.7 m) per minute.
 The final benefit of the system is that overspray is almost eliminated. Because of the controlled spray of the VAU variable spray ® nozzle and the unique design of the spray booth, overspray is kept to a minimum. This helps protect the bearings, drives and motors of other manufacturing equipment in the plant.
Adjusting the capacity, drop size and spray pattern for precise coverage is easy with Spraying Systems Co.'s VAU variable spray spray nozzle. For example, the atomizing air pressure can be reduced to produce a larger drop size. Or adjusting the fan air line pressure regulates the spray pattern and coverage without affecting the drop size or flow rate. The result is accurate, uniform spray distribution. The independent control of the liquid flow also offers various distribution patterns with the use of just one nozzle.
The VAU variable spray nozzle features seven different external mix spray set-ups with flow rates ranging from 0.74 to 47 gph (2.8 to 179 l/h). With the fan air in operation, a flat spray pattern is produced, while a round spray pattern is produced when the fan air is shut off. The low- to high-pressure atomizing range is 10 to 90 psi (0.7 to 6.2 bar) with a minimum of 35 psi (2.4 bar) air pressure required to operate the air cylinder.
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