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AutoJet Spray System Decreases Production Downtime
by 90%
 Application:
A major European carpet manufacturer needed an automated spray system
to apply a lubricant on carpet fibers while spooling multiple yarns
onto a master spool. This spray application is critical to the overall
productivity of the carpet mill because it prevents breakage of
the yarn during the weaving process on the carpet loom.
Problem: The system needed to spray carpet
fibers with an even coating of lubricant across the entire width
of the spool. The system had to maintain consistent coverage despite
variations in spray distance. Since the spray distance continuously
decreases as the spool is filled, the spray angle must be continuously
adapted to ensure coverage of the full width. For worker safety,
the system needed to minimize misting, and the system needed to
integrate seamlessly with the customer’s existing equipment.
Solution: The compact AutoJet Spray System
is controlled by a Model
2250 AutoJet Spray Controller, which accepts start and stop
signals from the loom. The Model 2250 controls the operation of
six Spraying Systems Co. VAU automatic guns, which are grouped into
three zones of two nozzles at a fixed height above the spool.
VAU automatic spray guns were chosen for this application
because they allow independent control of atomizing air, fan air
and liquid, which means that capacity, drop size and spray pattern
can be fine-tuned for precise coverage.
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Model 2250 AutoJet Spray
Controller
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VAU Automatic Spray Gun
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How the System Works: As the spool fills with
fibers, the spray height decreases from 900 mm to 300 mm. The AutoJet
Spray Controller automatically compensates by adjusting the fan
air pressure to the VAU spray guns, increasing the spray angle for
each gun to maintain total spray coverage. At the same time, atomizing
air is adjusted to minimize misting and overspray.
The spray controller provides closed loop control
by monitoring the system flow rate with an inline flowmeter and
adjusting as necessary. A constant flow rate is maintained by controlling
the speed of the variable frequency drive pump.
Spray nozzle plugging is minimized by automatically
cycling each spray gun’s clean-out needle rapidly at fixed
intervals to purge the orifice. The Model 2250 AutoJet Spray Controller
constantly monitors system performance and generates alarms in the
event of any irregularities.
Results: Before installing the AutoJet Spray
System to lubricate the fibers, yarns could break as many as 20
times per shift, bringing the production process to a halt each
time. Since the commissioning of the new system, line breaks have
been reduced to less than two per shift, allowing a single operator
to run four machines — one more than in the past.
The AutoJet Spray System increased annual production
2% and provided a payback period of less than six months.
CUSTOMER TESTIMONIAL
“AutoJet
Technologies listened to our needs and worked with us to develop
an innovative solution to our problem. Their software really enhanced
the performance of their spray hardware and the simplicity of their
design allowed us to install the system ourselves, maximizing our
budget.
AutoJet Technologies wasn’t
“just as good” or even “twice as good” as the
other vendors we contacted about this project. Their innovative
design and customer service made them at least five times as valuable
to us in this application.”
—Production Manager
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