This document discusses Patvin Engineering's paint circulation systems and green solutions. It provides an overview of Patvin's history and services, which include engineering design, turnkey projects, commissioning, training, and after sales support for paint circulation, sealer distribution, robotic glazing, and other systems. The document then focuses on green solutions for paint circulation systems, describing how traditional pneumatic systems can be replaced with intelligent electric systems using smart controls to reduce energy usage and costs. Specific benefits highlighted include decreased power consumption, reduced paint shear, lower maintenance needs, individual pump monitoring, and savings on energy usage compared to pneumatic pumps.

1. 1
Green Solutions in
Paint Circulation Systems
INDIA SURFACE COATING SHOW NOV 2015

2. ABOUT PATVIN
 Started 27 Years ago in 1987 Mumbai.
 Installed our first Large PCS 20 Years ago in 1995.
 Installed 2000+ Painting Circulation Systems in the last 20 Years.
 Completely ready Paint Circulation and Application lab since 9 Years (2006)
 Today we are a force of 200 strong team members dedicated to paint
circulation/ application and raring to go!

3. PATVIN ACTIVIES
 Engineering Design
 Turnkey Projects on EPC basis for :
Paint Circulation.
Centralized Sealer Distribution.
Robotic / Manual Glass Glazing.
Coded Cavity Wax Systems
Centralized Lubrication Systems.
 Commissioning and Training.
 After Sales Service and Annual maintenance
contract.

4. PATVIN ACTIVIES
 Engineering Design
P&I Drawing
3D Drawing

5. PATVIN ACTIVIES
Turnkey Projects on EPC basis for :
Paint Circulation.
Typical PCS Typical Piping

6. PATVIN ACTIVIES
 Turnkey Projects on EPC basis for :
Centralized Sealer Distribution.
1000 Kg Sealant Un-loaders Typical Drop Station

7. PATVIN ACTIVIES
 Turnkey Projects on EPC basis for :
Coded Cavity Wax Systems
Coded Gun
Coded Nozzles
Coded Application

8. PATVIN ACTIVIES
 Commissioning and Training. Service and parts

9. Green Solution in PCS - Introduction
Q. What is a Paint Circulation System ( PCS ) ?
A . A system that moves paints /coatings from a Can to the part
to be painted without attributing to any defect .
Pumping Module Pipe Network
Heat Exchanger System
Drop Point Station

10. Green Solution in PCS - Introduction
 Flow – If the flow varies or is inadequate painting is affected.
 Pressure – Low or High Pressure can affect Painting equipment and finish
quality.
 Temperature – Out of range temperature cause paint defects.
 Velocity – Paint movement below 60fpm cause shade variations and many
other defects.
 Shear – Damages Paint pigments thereby affecting end result.

11. Green Solution in PCS - Introduction
 Maintain uniform color and distribution of pigments, metallic and mica –
Maintain particle velocity 60 ft/ min +
 Maintain uniform viscosity by maintaining proper circulation rate ( shear )
and temperature
 Meet pressure and flow rate requirements of automatic and manual
stations
 Maintain suspension which prevents settling of paint
 Provide a low shear system design
 Provide the best solution to meet all functional objectives with less energy
consumption thereby lowering cost of operation ( cost per unit produced )

12. Green Solution in PCS
 What is the need for an intelligent fluid handling system?
 Many organizations have a growing concern for the environment.
 Businesses play a critical role in developing and utilizing environmentally
sound products.
 Awareness of the impact fluid handling equipment can have on the
environment to find ways to reduce negative effects.
• Reduction of Energy
• Compliment with governmental regulations
• Customer demands for eco-friendly technology
• Protecting the environment

13. Green Solution in PCS
 We needed to develop an intelligent fluid handling
system so it was a natural thought to create energy
saving simply by using less energy.
UNDERSTAND NATURAL INTELLIGENCE…
…CREATE ARTIFICAL
INTELLIGENCE

14. Green Solution in PCS - Logic
 BRUSHING YOUR TEETH WITH THE TAP RUNNING
 ≈ 15 Liters

15. Green Solution in PCS - Logic
 BRUSHING YOUR TEETH TURNING THE TAP ON AND OFF
 ≈ 1 Liter

16. Green Solution in PCS
Now develop a fluid handling system, capable of…
…“Turning on and off the tap” self sufficient.
The patented SMART control:
”Tap OFF mode” - Open Loop
when paint needs to be circulated but is not required at any take off
point.
”Tap ON mode” - Closed Loop
when paint is required maintain required pressure but only supply the
flow needed at the user points

17. Green Solution in PCS – Traditional

18. Green Solution in PCS – Electrical
Pilot BPR
Pressure
Sensor

19. Green Solution in PCS - Differences
Typical Pulsation of most Paint systems after Surge suppression
Typical Pulsation of a Asymmetrical Design Electrical system

20. Green Solution in PCS
Factors To Consider When Comparing Running Costs
Pneumatic Pump Operation Cost (Indirect Energy Source)
 kW to Operate Air Compressor
 kW to Operate Air Drier
 kW lost due to pipework pressure drops and air leaks
 High System Installation & Maintenance Costs
 Air Motors may require Heaters to prevent freezing
Electric Pump Operation Cost (Direct Energy Source)
 kW to Operate Electric Motor
 Low System Installation & Maintenance Costs

21. Green Solution in PCS – Current
Pneumatic Solutions
Filtration
Pipework
Compressor Drier
Typical Conversion Losses = 75~80%
Ie. A typical Pneumatically driven PCS Pump requires 4x the
amount of power compared to a Smart Electrical Pump System

22. Green Solution in PCS
Smart Control
The ‘Smart’ system design provides for
two modes of operation.
Open Loop
Back Pressure Regulator „Unloaded‟ to
reduce the paint line pressure and
Pump pressure requirement
Pump motor will be driven to run at a
set minimum speed (Min Paint velocity)
Back Pressure
Regulator
(air pilot)
Closed Loop
Paint pressure maintained by the back-pressure regulator
Pressure sensor monitors System Pressure
Pump speed is controlled to maintain system pressure to the
pre set point value

23. Green Solution in PCS
23
Example of Open Loop Control for Basecoat System Colour
Open Loop, Pump Pressure 12 bar System Colour in use
with a Flow Rate of 16L/min. during production.
Pressure/Flow set to
production requirements.
Typical relationship between vehicle travel through the
Spraybooth versus Paint Flow/Pressure.
Hand ‘Touch in’ Basecoat Bells ‘Pick up’ Station

24. Green Solution in PCS
Example of Smart Closed Loop Control for Basecoat System Colour
Closed Loop, Pump 12 bar System Colour in use.
Flow rate varies to meet required system demand
(up to design requirement 16L/min)Closed Loop, Pump 12 bar
System Colour Ready for
use. Flow rate 9.0L/min
Duration
Pressure/Flow
Typical relationship between vehicle travel through the
Spraybooth versus Paint Flow/Pressure.
Hand ‘Touch
in’
Basecoat Bells ‘Pick up’ Station
Product I-Dent reader
Colour requirement
information sent to Mix
Room control panel

25. Green Solution in PCS
25
Example of Smart Control for Basecoat System Colour

26. 26
Pump Speed
(Hz)
Pump Pressure
(bar)
OPEN LOOP OPEN LOOPCLOSED LOOP
CLOSED LOOP DURING APPLICATION
Pump Speed (Hz)
Pump Pressure (bar)
CONSTANT
PRESSURE
≈ USED
ENERGY
REDUCE ENERGY
USED

27. Cost kWh 8.00 Average Day/Night Cost Currency INR Utility Company Charge
Power kW 8.05 Pneumatic Pump ₹ 562,598.40 Air Compressor Annual Energy Cost
Power kW 0.25 Smart Controled Electric
Pump
₹ 17,472.00 Annual Energy Cost (0.8kW £594.05)
Annual Saving ₹ 545,126.40 Per Pump
1.00 Pump Mix Room ₹ 545,126.40 Basic Annual Saving
Time
Hours
Power
kW Pressure bar Flow Event Remarks
22 0.22 5 7.5L/min Open Loop Paint not required at spraybooth
1.5 0.50 14 9.0L/min Closed Loop Paint required at spraybooth
0.5 0.80 14 16L/min Closed Loop Paint 'In Use' dynamically at spraybooth
24 0.25 --- --- --- Average Power Used per 24 hr Day
Paint System Energy Costs
• With Smart Control we decrease Power consumption from 0.6 kW 24/7 to
0.25 kW for average power usage of typical Paint system 24/7.
• Further decreasing annual running Costs
Green Solution in PCS

28. Green Solution in PCS
Cost Savings by adopting Electric Drive Pump
• Reduction in Compressed Air Usage & Maintenance costs
• Lower Power Consumption – Reduction in Running Cost
• Reduction of Pump Speed and Pressure during Non-Production hours.
• Incentives for Energy Saving Investments
Additional Cost Savings by adopting Smart Control
• Supply paint at required pressure and flow only when needed for actual
production.
• Further savings on Pump running costs
• Longer life for Pump wear parts
• Reduced maintenance costs
• Potential paint saving due to reduction of shear
• Smart System Control of Individual Pumps
• Smart Controls allows Monitoring of pump performance life and
provides information on Maintenance schedules.

29. Green Solution in PCS
 Review on Key Benefits:-
• Savings on Energy Usage v Pneumatic Pumps
• Energy Conversion to Compressed Air
• Air Conditioning Equipment – Driers, Heaters
• Impact on Environment
• No Compressed Air supply requirement – Pipework Installation, Leak
potential
• No Pump Air exhaust
• Ambient Noise Reduction
• Reduced Contamination Risk
• Operation
• Smart Control of Each Pump
• Paint supplied at required pressure and flow only when needed
• Reduced Paint Shear
• Maintenance
• Maintenance of all Compressed air services
• Reduction in Maintenance Tasks
• Reduction in Annual Spare Parts Budget
• Individual Pump Monitoring and data recording

30. THANK YOU
Mr. Mangesh Pawar.
PATVIN ENGINEERING PVT LTD.
Navi Mumbai; INDIA
www.patvin.co.in