We’ve heard it before – you’re doing everything you can to save money on compressed air energy, but it’s not working. You’re purchasing energy-efficient compressed air system equipment yet your energy costs aren’t as low as they could be or maybe even should be. Compressed air systems are comprised of a lot of different equipment which can idle when they aren’t needed. Even though your equipment is energy-efficient your compressor, blower, dryer, etc. are all reacting to the needed output demanded.
There’s another piece of equipment that could help.
Introducing the Kaeser Sigma Air Manager 4.0 (aka SAM 4.0)
The award-winning Kaeser Sigma Air Manager 4.0 (SAM 4.0) efficiently gives you more air for less money while increasing productivity. SAM 4.0 has adaptive controls, predictive maintenance, data storage, and analysis – all while maintaining a reliable, consistent, and efficient supply of compressed air. It’s a device that works with your entire system, but also provides a display to enable you to understand how it’s controlling your system.
Management of your entire compressed air system
Kaeser’s Sigma Air Manager 4.0 ties in all of your compressed air system equipment including compressors, blowers, and vacuums into a secure Sigma network. That control into one device enables you to manage your entire facility or industrial plant.
Because it controls the entire system, you’ll have steady pressure, energy savings, and efficient use of air!
Messaging and maintenance
In addition, built into SAM 4.0 is a predictive maintenance reminder and messaging abilities. The device communicates exactly what maintenance needs to be performed and when you should do it. No more mind-reading! That functionality obviously makes it easier for you to schedule maintenance, prepare your workforce for maintenance, and get service technicians on the calendar. It also makes it easier for your compressed air service technicians to keep you up and running, eliminating downtime.
These built-in features ensure you never miss preventative maintenance, maximize efficiency, and maximize the life of your compressor and equipment.
Easy-to-use touchscreen technology
SAM 4.0 features a user-friendly 12-inch color touchscreen, which means it’s fairly easy to use. The home screen shows real-time operating status, power consumption, pressure history, flow, and error messages. This data can be accessed anytime and anywhere, giving total control to the facility manager.
Ready to use SAM 4.0?
Are you ready to get steady pressure, receive communication about issues and reports on analytics, and save money on energy? Our Michigan, South Carolina, northern Ohio (near Toledo), and southwestern Ohio (near Cincinnati and Dayton) teams can install SAM and get you up and running. We’ll conduct training to ensure you understand what you’re seeing, too. Plus, we can maintain your system and be there if SAM communicates any issues – 24 x 7, 365 days a year.
There are lots of signs your air compressor needs service — it’s dripping oil, it’s smoking, it’s noisier than usual, etc. Those are obvious. But there are times when your compressor needs service and it’s not as obvious. Here are a few:
Run-time or calendar
Consider run-time as part of your preventive maintenance. We recommend annually or every 2,000 hours, whichever comes first.
Weather
Extreme weather can cause big problems to your air compressor, either when it’s too hot or too cold. One tip for hot weather: try power washing your air compressor.
Plant conditions
Dirty, dusty, and other poor environmental conditions can cause issues with your air compressor. For these environments, we recommend more frequent service.
Higher costs and energy
Another good time to get service or an audit is when you notice higher-than-expected energy bills. You may even think you need a new compressor when you need to determine what’s wrong with your current setup. Easy ways to determine include an air demand analysis, leak audit, or other analysis to investigate the culprit.
Contact us for service
At Elevated Industrial Solutions, we provide maintenance and audits before your air compressor becomes an emergency. Our technicians have experience taking care of every major brand of compressor. And we service locations across the tri-state area – Ohio, Kentucky, and Indiana – as well as South Carolina.
We even have 24/7 service for emergencies. (We just hope it doesn’t come to that!)
Spray booths, also known as paint booths, are definitely important tools that many industrial businesses use to ensure their jobs are finished right. Having the right one can certainly help you achieve success and keep you from fuming over the results. Like any large piece of equipment, you will want to tailor your booth to suit your specific needs and your physical space. Your decision will include many factors, such as cost, product size, desired finish quality, and more. Fortunately, many configurations are available, so you’ll be able to choose the setup that best fits your application. With a little research, we’re sure your spray booth requirements will help guide you to the best decision. Then, you can “go with the flow.”
Consider this article a primer for your paint booth decision. Let’s look at various paint booth configuration options and their features. Here, we’ll be checking out products from two high-quality companies, Rohner and RTT Engineered Solutions (formerly Col-met). They both offer far more options than can be covered in one article, but this blog post will give insight into various available styles and their strengths and weaknesses.
The rock band Queen has told you for years, with their song “Bohemian Rhapsody,” that, “Anyway the wind blows, doesn’t really matter to me.” It doesn’t sound like they were under pressure after all, but they must not have been in the market for a quality paint booth either!
Suppliers
Here’s a brief introduction to the two outstanding suppliers covered in this article.
Rohner
When it comes to manufacturing paint booths, industrial spray booths, truck booths, large equipment, and custom paint booths, Rohner is a global leader. They offer spray booths that have been thoughtfully designed for an assortment of applications. Rohner products have been engineered with efficiency, safety, and cleanliness in mind. These booths feature high-quality materials and industry-leading technology. Also, their products are proudly made in the USA.
RTT Engineered Solutions (RTT)
RTT boasts top engineers in the industry, which means they’re ready and able to deliver creative solutions for your company’s requirements. RTT offers a line of energy-efficient, high-quality, and environmentally-optimized paint booths, addressing a broad range of applications. Their booths are easy to install, efficient, and have you covered for both solvent and water-based coatings.
Now that you’ve met the players, it’s time to look at some configurations.
Open-face booths
One popular type of paint booth is the Open-Face Paint Spray Booth. With this style, the airflow enters from the front and moves through the work area into a filtered-exhaust chamber at the rear. Once it arrives there, it’s drawn up through an exhaust plenum where it is discharged from the exhaust stack into the atmosphere.
Rohner offers these booths as an efficient and economical method of applying paint to various product sizes. Access is easy, too. They even come with modifications – retrofitted with supply filtration and doors.
RTT refers to their open-face booths as Open Front Booths. The company provides a line that supplies cost-effective solutions for batch applications and conveyorized operations. Possessing a good, flexible design and solid build quality, it’s worth taking a look at the booths that RTT has available to you. They can produce custom sizes and designs based on your location’s specific needs (including conveyor and crane slots/openings).
Open-front bench booths
Another useful booth option is the Open-Front Bench Paint booth. RTT manufactures booths in this style, handy for applying paint to small- and medium-sized parts. It’s a variant of their open-front booth design. These booths are great for batch production systems, and many smaller shops love this model for painting limited numbers of small items. These booths come in an array of standard sizes to maximize your floor space (and custom sizes are available too). Air flow enters the open front of the booth, continues through the working area, and into a filtered exhaust chamber at the rear. Once there, the filtered exhaust air is drawn into the exhaust plenum and discharged through the exhaust stack into the atmosphere.
Downdraft booths
Let’s switch gears and talk about Downdraft booths. Due to their design, downdraft spray booths can produce clean finishes. They also provide superior control of the airflow. This style efficiently handles overspray and can reduce the time you spend on prep. Less overspray waste, improved finishes, and better airflow are just a few reasons you’ll find them in such places as first-class auto-body shops and specialty vehicle places. They function by taking in air through the ceiling and moving it down through the floor where it works its way into the exhaust chamber. One thing you should know — this layout can carry supplementary expenses; for example, construction may be required for the exhaust plenums. Also, downdraft booths typically require about a third more air volume to operate than the cross-draft configuration. That means you’ll see a corresponding increase in operational costs too.
You’ll find that Rohner supplies full Downdraft booths. They have an assortment of sizes and even expandable configurations. Rohner also has solutions for your custom finishing requirements and large equipment and truck needs. You’ll find their product line of these popular downdraft booths out in the world, working in conveyorized paint shops, laying down beautiful automotive finishes at body shops, and even spraying aerospace and oversized parts.
When it comes to downdraft booths, don’t think that RTT is sitting this one out! They also offer a wealth of solutions, including downdraft trucks and large equipment booths. The RTT EZ Pit Downdraft line is a popular choice for applications in the automotive industry. They come in a variety of sizes and their offerings include Standard Duty, Heavy Duty, and Xtreme Duty. Whichever duty calls … they have you covered. There are options available concerning the pressurized, non-pressurized, solid back, reverse flow, and drive-through set-ups. They have modified and industrial selections, too. The modified versions can be found servicing such industries as truck, rail, and aviation, along with a host of other large-scale finishing situations. Their industrial booths are completely customizable. They can be constructed in all manner of sizes and configurations based on your individual needs.
Cross-draft spray booths
Depending on your business needs, a cross-draft booth might be the way to go. They’re extremely popular and typically offer increased affordability combined with a more straightforward installation. Of course, every design has advantages and disadvantages. With the cross-draft layout, overspray and dry-spray can lessen the quality of your finishes. These booths can also increase the risk of contamination. Due to the horizontal airflow, you’ll have to be concerned with floor contamination. If your business demands an extremely high-quality finish, you’ll probably want to go back and take another look at the downdraft section!
Make no mistake, cross-draft booths are wonderful choices for many companies, and fortunately, Rohner has multiple options. Their standard cross-draft design works by drawing non-pressurized, and fresh filtered air out of the supply plenum. The air then flows horizontally throughout the complete work area. It exits through a wall exhaust plenum or pant leg on the far end. This set-up is excellent for finishing an assortment of products both big and small. They can even be set-up as drive-in/drive-out, or flow-through operations. Rohner has efficiently filled the needs of heavy-equipment customers with the scalability and low operating costs for handling heavy equipment. These cross-draft booths are excellent choices for fleet refinishing, providing an automotive-grade quality. Recreational vehicles (RVs) also benefit when collision repairs are necessary.
If the standard cross-draft set-up isn’t quite what you need, Rohner may still be able to save the day with one of their modified cross-draft paint spray booths. These modified versions improve the airflow by guiding the air down from intake filters in the ceiling and drawing it to the back before exiting through the exhaust plenum. With this combination, you’ll receive some benefits from both the downdraft and cross-draft arrangements. Additionally, these can be configured for drive-in/back-out and flow-through applications. Rohner has found clients for their modified cross-draft spray booths ranging from aerospace components (for reduced chemical exposure to the operator), robotic coating applications, and military maintenance sites, where customers take advantage of the extra-wide doors to deal with huge and heavy pieces of machinery. They also offer industrial options.
You’ll discover that RTT has extensive experience and solutions in the cross-draft market as well. Their EZ Classic line of cross-draft booths gives you easy installation (as you might have guessed by the EZ in the name!). Featuring a number of configurations and sizes, you’re likely to find economical answers to your spray booth needs. RTT also provides a line of truck and large equipment booths for various industries. Once again, you have your choice of pressurized, non-pressurized, solid back, drive-through and reverse flow, and their Standard Duty, Heavy Duty, and Xtreme Duty options.
Side downdraft spray booths
Another option to consider is a side downdraft spray booth. These have some of the same benefits as the aforementioned downdraft style. This design draws air from the ceiling but exhausts it from the sidewall. You may find this choice appealing as it prevents you from extensive (and expensive) concrete floor modifications. However, the additional ductwork required can add costs. The gravity-assisted airflow is a huge benefit to this design. It provides a nice, even pattern of airflow. With this layout, you’ll find more uniformity in your airflow versus the cross-draft arrangement and better contaminant control. The side downdraft style may be the way to go if you’re aiming for a finish comparable to a downdraft booth but don’t want to (or can’t) modify your facility to accommodate the downdraft model. It may also work best due to cost savings. Like all of the other booth options, you do need to be aware of potential issues such as exhaust fans and penetrations in your roof impacting overall cost. Employees may also be annoyed by “wearing” overspray, needing additional gear to keep them safe.
Once more, if the side downdraft style is for you, Rohner has options. They carry a line that can be designed for both flow-through, or drive-in/back-out production lines. Delivering good airflow in large spaces, you’ll see this style employed for tasks such as aircraft finishing. It’s also a natural choice for heavy equipment, which may require the downdraft level of finish while avoiding the concerns of testing the structural rating of the pit!
Like their cross-draft choices, RTT delivers a product line of economic side downdraft booths. We’ll start with the EZ Side Downdraft line. If you’re not able to install a pit, this can be a truly great option. Yet again, RTT offers these in a variety of configurations and sizes. They come to the rescue for regular applications, as well as servicing the bigger crowd with a line-up of Standard Duty, Heavy Duty, and Xtreme Duty choices. By now, you’ve probably figured out they can provide pressurized, non-pressurized, solid back, reverse flow, and drive-through booths.
Trust Lane for your coating and finishing projects
Not to paint ourselves in a corner, but there are more styles of spray booths that could apply to your specific needs. Choosing the best booth is much like laying down any good paint job … it starts with excellent prep work.
At Lane, we can help you assess your coating and finishing needs as well as understand your company’s goals. We thoroughly listen to our customers as partners, helping you be more efficient and effective. Afterward, we can recommend a product based on our expertise. But we’re not a “one-trick pony,” we provide more than just RTT and Rohner coating and finishing systems. We carry some of the most trusted brands in coating and finishing equipment, as well as abrasives, adhesives, tapes, tools, safety gear, and more. Our goal is to be your trusted partner for every industrial need you have.
PVC is lightweight, inexpensive, and easy to purchase at any local building supply store, making it all the more attractive when it comes to selecting piping materials for a compressed air system.
Using PVC, however, has its risks and in certain areas, it may not be code compliant. It also carries a static charge which can lead to spontaneous combustion in certain dust-filled environments, it’s subject to bursting (yes bursting), and the adhesives used in installation are not compatible with all types of compressor oils. Despite the safety issues, many small shops and even some larger plants continue to use it.
A couple of years back we were installing a compressor at a medical device manufacturer in Colorado, and we noted the plant’s wide use of PVC piping. I asked the shop manager (who was three weeks from retiring) whether they’d had any issues with PVC cracking or bursting under pressure. He said yes, many times. “Pieces fly across the room.” He would just replace them. “No one’s been hurt so far…”
In a room with 4 huge, expensive injection molding machines and many employees, he saw no need to change. Different strokes, I guess.
Here are two more examples:
1. The remains from a 2” PVC pipe burst at a manufacturing plant in Texas. Thankfully no injuries, but some unscheduled changing of underwear.
2. In a small customer paint shop in Texas, a large section of PVC pipe burst during normal operation. Again, there were no injuries.
If you have PVC pipe in your shop or factory, make sure it’s pressure rated and regularly check it for signs of cracking.
For those of you considering using PVC pipe, I urge you not to—it’s really not worth the risk.
Door and window installations are the bread and butter for construction companies and general contractors. New construction and replacing windows and doors can be lucrative. But the industry is highly competitive. How can you differentiate your business from your competition to get those good-paying jobs? And how can you keep installation for your windows and doors low?
Flashing and sealants help give your customers the value and quality installation they expect, propelling you above your competition. Plus, these products are cost-conscious, especially when it comes to eliminating the need to do a project over.
At Elevated Industrial Solutions (Elevated) we list our favorite door and window installation products for flashing and sealing … as well as why you may need one versus another.
Flashing solutions
You probably know this, but it merits revisiting. The first line of defense for air and water intrusion is a good seal on the full untrimmed opening for a window or door (also known as the rough opening). When flashing is installed and sealed correctly, water is directed away from the window to keep a home dry and eliminate rot, mold, and mildew. But not all rough openings are created equal (different materials, sizes, shapes, etc.).
Flashing typically comes in three varieties with these advantages and disadvantages:
Metal flashing is durable, but not as flexible
Vinyl flashing is flexible, but not as durable
Tape flashing is easy to install, but often not as durable in hotter areas
Liquid flashing is a newer innovation in flashing
Find the right flashing for your project from two top brands known for durability and quality. Both Protecto Wrap and OSI products meet local code requirements and national building standards while providing long-lasting performance your customers can count on that won’t break the bank. When they’re used, your jobs will be known as high quality … while reducing long-term liabilities from failure.
Some of the products below may even surprise you!
Protecto Wrap
Protecto Wrap has waterproof membranes that provide high-quality waterproofing. They’re even easy to install. Plus, they have durability and staying power – a preference for construction workers and general contractors since 1952. Here are a few of the products we think are some of their finest:
BT20XL butyl
This 20mil peel–and–stick, self-adhering butyl (the adhesive component) laminated on a polyethylene film provides a tough, durable, easy–to–apply membrane. The product sticks to most common building materials to provide a tight seal while still enabling joint movement. Best of all, it’s compatible with all types of window construction substrates including wood, wood clad, aluminum, fiberglass and vinyl windows and doors, and PVC.
A 120–day UV resistance aids in weather protection during delays in siding or cladding installation.
Super stick building tape
This tape is a primer-less flashing tape for window and door installations. Easy to apply in all temperatures, great for cold climate installations. The tape has the same benefits of butyl or asphalt-based flashing without the primer or the gassing, VOCs, CFCs, and HFCCs. That’s why construction workers and contractors use this so often – it’s a faster turn-around time and fewer customer complaints when replacing windows.
12-month UV exposure is great for new construction where timelines and exposure times can be longer than expected.
Sill pan flash
This one-piece, continuous sill flashing requires no cuts or “butterfly” corner guards. That means, your installation jobs are faster. Also, most people can install these, reducing the need (and expense) for experts to do the cutting or installation. It even has lower product waste. It’s a great option for those 90-degree corners without adding substantial material to the rough opening dimension.
Sealants
Okay, the flashing is done. You’re not out of the woods yet. You may need a sealant to protect your window or door. When it comes to sealants there are lots of options. A few of these products stand out – handling even the toughest climates and jobs.
OSI
Outside of flashing, OSI has a few sealant products that can handle tough jobs with ease. OSI is approved and recommended by many of the top manufacturers because of its durability.
Quad Max
It’s called “Tougher than the Elements” for a reason. This is the premier sealant that can handle the toughest climates. Specifically designed for durability, colorfast, and flexibility, this sealant offers a variety of features, including color matching. OSI’s lab has created exact color matches for all the most popular window and siding manufacturers.
Although some construction workers and general contractors have issues with color matching, that shouldn’t stop you. We stock 30+ options, including the most popular colors in use today. And because we’ve been in business since 1955, we can help select the perfect match for whichever window or siding you’re installing.
Quad Foam
This product is insulating foam for windows and doors. Quad Foam accurately and completely fill voids around windows and doors without stressing or racking. Using an applicator, you can get pinpoint precision to create a tight seal around these irregular rough openings.
BOSS
According to BOSS’s website, their line of products is engineered to the highest quality to ensure maximum performance for the industrial, construction, pool and spa, HVAC/R, manufacturing housing, and RV markets.
363 Acrylic Latex
BOSS 363 is the go-to paintable acrylic latex caulking. Low shrink, non-yellowing, and paintable are all characteristics that will keep callbacks to a minimum. It’s versatile caulking that puts the finishing touch on interior trim while making an airtight seal.
Elevated is on the job with you
Construction workers or general contractors, we have tools and equipment to help you finish your projects on time and on budget. Regardless of whether you love BOSS, OSI, Protecto Wrap, or a different brand, Elevated is with you. We have a variety of brands and products to help you solve your specific window and door installation challenges. Our team has the expertise to get you the right supply or equipment every time.
Talk to our experts today to see how we can help you finish your jobs on time and under budget.
