The document discusses ways to minimize paint waste in auto body shops. It describes environmental and health concerns from hazardous paint waste and identifies common sources of waste like overspray and mixing errors. Methods to reduce waste are outlined, including proper inventory management, mixing small amounts of paint, computerized mixing systems, calibrated liners, painter training programs, and spray booth functions. The goal is to improve efficiency, reduce emissions and disposal costs, and protect worker health.

1. Minimizing Paint WasteMinimizing Paint Waste

2. Environmental & Health ConcernsEnvironmental & Health Concerns
 Hazardous wasteHazardous waste
 Mixed coatings and solventMixed coatings and solvent
 Toxic, flammableToxic, flammable
 Air emissionsAir emissions
 Toxic constituentsToxic constituents
 Toluene, xylene, MEKToluene, xylene, MEK
 Smog forming VOCsSmog forming VOCs

3. Paint Waste SourcesPaint Waste Sources
 Mixing roomMixing room
 OverestimateOverestimate
 OvermixOvermix
 OversprayOverspray
 TechniqueTechnique
 EquipmentEquipment
 Re-work jobsRe-work jobs
 Color not matchedColor not matched
 Dust and dirtDust and dirt
 Finish qualityFinish quality

4. Manage InventoryManage Inventory
 Just-in-time orderingJust-in-time ordering
 First-in, first-outFirst-in, first-out
 Keep containers closedKeep containers closed
 Mixing banksMixing banks

5. Thickness MatchingThickness Matching
 Mix in small amountsMix in small amounts
 Start with 8 oz. or lessStart with 8 oz. or less
 Spray out on test panelsSpray out on test panels
 View and compare in natural lightView and compare in natural light
 Measuring cups or Preset despensingMeasuring cups or Preset despensing
 Expertise of other paintersExpertise of other painters
 Record mix informationRecord mix information

6. Paint MeasurementPaint Measurement
 Computerized mixingComputerized mixing
systemsystem
 Tracks product use andTracks product use and
VOCsVOCs
 Reports for air districtReports for air district
 Automated paintAutomated paint
dispenserdispenser
 Minimizes over-poursMinimizes over-pours
 Minimize paint transfersMinimize paint transfers

7. Track and TroubleshootTrack and Troubleshoot
 Record each stepRecord each step
 Estimated amountEstimated amount
 Actual amount mixedActual amount mixed
 Left overLeft over
 Compare estimated and actual paint used toCompare estimated and actual paint used to
refine estimatingrefine estimating
 Compare paint orders with workloadCompare paint orders with workload
 Work with painter to resolveWork with painter to resolve

8. Paint left overPaint left over
 Mix into ground coatMix into ground coat
 Cover hard to hide colorsCover hard to hide colors
 Under dark color coatUnder dark color coat
 Will it change regulated VOC content?Will it change regulated VOC content?
 Check with air districtCheck with air district
 Door interiors, edging, jambingDoor interiors, edging, jambing
 Save popular colors for later useSave popular colors for later use

9. Calibrated LinersCalibrated Liners

11.  The benefits of using the paint gun liner system include:The benefits of using the paint gun liner system include:
 •• Paint waste is reduced because it is not transferred from a separatePaint waste is reduced because it is not transferred from a separate
mixingmixing
 cup,cup,
 •• Saves time when mixing more than one batch of coating at a time,Saves time when mixing more than one batch of coating at a time,
 •• Easier and faster paint gun cleaning,Easier and faster paint gun cleaning,
 •• Cleaning requires much less solvent and generates less waste, andCleaning requires much less solvent and generates less waste, and
 •• Reduces product purchase and waste disposal costs.Reduces product purchase and waste disposal costs.
 You should consider the following:You should consider the following:
 •• The liners are refillable but cannot be cleaned with solvents for reuse.The liners are refillable but cannot be cleaned with solvents for reuse.
 •• Used liners contribute to your shop’s overall waste generation and mustUsed liners contribute to your shop’s overall waste generation and must
be managed properly.be managed properly.
 Most shops have found them to be non-hazardous waste. If you are notMost shops have found them to be non-hazardous waste. If you are not
sure how to manage wastesure how to manage waste
 liners, check with your local Certified Unified Program Agency (CUPA).liners, check with your local Certified Unified Program Agency (CUPA).

12. AdvantagesAdvantages
 Mix in cup linerMix in cup liner
 Mix more than one batch atMix more than one batch at
a timea time
 Increases applicationIncreases application
efficiency and reduces paintefficiency and reduces paint
oversprayoverspray
 Cover and save mixed paintCover and save mixed paint
for a limited timefor a limited time
 Reduces cleaning solventReduces cleaning solvent
and wasteand waste
 Do not need to clean paint potDo not need to clean paint pot
 Reduces laborReduces labor
 Increased productionIncreased production

13. Job PlanningJob Planning
 Primer and clear coat back-to-backPrimer and clear coat back-to-back
 Tintable primer systemsTintable primer systems
 Schedule waterborne primer application to allowSchedule waterborne primer application to allow
drying timedrying time
 Remove part before paintingRemove part before painting
 No masking neededNo masking needed
 Reduces oversprayReduces overspray
 Streamlines processStreamlines process

14. PaintingPainting
 Spray efficiencySpray efficiency
 Finish qualityFinish quality
 Transfer efficiency (TE)Transfer efficiency (TE)
 How much paint gets on the surfaceHow much paint gets on the surface
 Build efficiency (BE)Build efficiency (BE)
 Amount of build (mils) applied on surface compared to amountAmount of build (mils) applied on surface compared to amount
sprayedsprayed
 Many variables effect spray efficiencyMany variables effect spray efficiency
 TechniqueTechnique
 Equipment and settingsEquipment and settings
 Correct use of productCorrect use of product
 Part geometryPart geometry

15. Improve Spray EfficiencyImprove Spray Efficiency
Poor techniquePoor technique
 Wastes paintWastes paint
 More clean-upMore clean-up
 Painter laborPainter labor
 Paint technician trainingPaint technician training
 TechnologyTechnology
 Higher efficiency spray gunsHigher efficiency spray guns
 Targeting device for training and applicationTargeting device for training and application

16. Painter TrainingPainter Training
Painters learn to apply paint more efficientlyPainters learn to apply paint more efficiently
 Hands-on trainingHands-on training
 Students practice proper techniqueStudents practice proper technique
 Techniques for specific coatingsTechniques for specific coatings
 I-CAR training centersI-CAR training centers
 Paint manufacturer trainingPaint manufacturer training
 Community college automotive programsCommunity college automotive programs
 IWRC STARIWRC STAR ®® Program,Spray Technique Analysis and ResearchProgram,Spray Technique Analysis and Research
 http://www.iwrc.org/STAR/STARschools.htmhttp://www.iwrc.org/STAR/STARschools.htm
 LA Trade Technical CollegeLA Trade Technical College
 IWRC STAR training for defenseIWRC STAR training for defense
 http://www.star4d.orghttp://www.star4d.org
 ARB P2 web page- auto refinishingARB P2 web page- auto refinishing
 http://www.arb.ca.gov/coatings/p2/overview.htmhttp://www.arb.ca.gov/coatings/p2/overview.htm

17. TechnologyTechnology
 LaserPaintLaserPaint™™
 Application technique and targeting toolApplication technique and targeting tool
 Allows painter to:Allows painter to:
 Maintain correct angle and distance for consistentMaintain correct angle and distance for consistent
coveragecoverage
 Optimize overlapOptimize overlap
 Reduce oversprayReduce overspray
 Developed by Iowa Waste Reduction CenterDeveloped by Iowa Waste Reduction Center
(IWRC)(IWRC)
 http://www.laserpaint.ushttp://www.laserpaint.us

18. Cost: $300 includes mounting
bracket and training CD
LaserPaint tool developed by IWRC
http://www.laserpaint.us

19. Environmental TechnologyEnvironmental Technology
VerificationVerification
 LaserPaintLaserPaint
 ARB certified performance claimARB certified performance claim
 15% volume reduction average15% volume reduction average
 USEPA environmental technology verification (ETV)USEPA environmental technology verification (ETV)
May 2000 http://www.epa.gov/etv/verifications/vcenter6-May 2000 http://www.epa.gov/etv/verifications/vcenter6-
5.html5.html
 High TE Spray EquipmentHigh TE Spray Equipment
 ETV report http://www.epa.gov/etv/verifications/vcenter6-ETV report http://www.epa.gov/etv/verifications/vcenter6-
16.html16.html

20. Painter TrainingPainter Training
 Virtual Paint- computer simulated trainingVirtual Paint- computer simulated training
 http://www.virtualpaint.us/http://www.virtualpaint.us/

21. Virtual PaintVirtual Paint
 Painters learn proper techniquePainters learn proper technique
 Reduces waste and costsReduces waste and costs
 AdvantagesAdvantages
 No paint waste- booth and filters, equipment, clothingNo paint waste- booth and filters, equipment, clothing
 No air emissionsNo air emissions
 No clean up wasteNo clean up waste
 DisadvantagesDisadvantages
 High cost of technologyHigh cost of technology
 AvailabilityAvailability

22. Paint Spray BoothsPaint Spray Booths

23. Functions of Spray BoothsFunctions of Spray Booths
 Facilitates cleaner paint jobsFacilitates cleaner paint jobs
 Contains oversprayContains overspray
 Collects wasteCollects waste
 Provides clean air during paint operationsProvides clean air during paint operations
 Provides well lit area, devoid of dustProvides well lit area, devoid of dust
 Protects worker’s healthProtects worker’s health
 Confines harmful emissions in one areaConfines harmful emissions in one area
 Prevents workers outside of booth from inhaling solvent emissions andPrevents workers outside of booth from inhaling solvent emissions and
paint particlespaint particles
 Workers painting within booth should wear personal protective equipmentWorkers painting within booth should wear personal protective equipment
 Monetary savingsMonetary savings
 Reduces operation costsReduces operation costs
 Lowers labor costsLowers labor costs
 Reduces material costsReduces material costs
 Filters paint particles from air before exhausting it into theFilters paint particles from air before exhausting it into the
atmosphereatmosphere

24. Types of Paint Spray BoothsTypes of Paint Spray Booths
 Spray booths provide uniform airflowSpray booths provide uniform airflow
 Two most common types of spray boothsTwo most common types of spray booths
(1) Cross draft spray booth(1) Cross draft spray booth
(2) Down draft spray booth(2) Down draft spray booth

25. Cross Draft Spray BoothCross Draft Spray Booth
 Air is drawn in across filters on the front end of theAir is drawn in across filters on the front end of the
room into filters located on the opposite end of theroom into filters located on the opposite end of the
room.room.

26. Down Draft Spray BoothsDown Draft Spray Booths
Air is pulled down through inlet filters on the ceilingAir is pulled down through inlet filters on the ceiling
into exhaust filters located on the floor.into exhaust filters located on the floor.

27. Combination Drying BoothsCombination Drying Booths
 Two distinct operating cyclesTwo distinct operating cycles
(1) Painting(1) Painting
(2) Heated drying cycle(2) Heated drying cycle
 Decreases curing timeDecreases curing time
 High productivity due to fast processing timeHigh productivity due to fast processing time
 Allows for good finish quality and reduces re-workingAllows for good finish quality and reduces re-working
 Conserves energyConserves energy
 Uses recirculating airflowUses recirculating airflow
 More cost effective over lifespan of equipmentMore cost effective over lifespan of equipment
 Reduces costsReduces costs
 Operation and maintenanceOperation and maintenance
 LaborLabor

28. Spray Booth ConsiderationsSpray Booth Considerations
 ServiceabilityServiceability
 Select from a vendor that offers maintenance, support, and warrantySelect from a vendor that offers maintenance, support, and warranty
 Choose a vendor that is accessible to reduce downtime whenChoose a vendor that is accessible to reduce downtime when
replacement parts and/or repairs are neededreplacement parts and/or repairs are needed
 LightingLighting
 FluorescentFluorescent
 Runs coolerRuns cooler
 Consumes less energyConsumes less energy
 High-Intensity Discharge (HID)High-Intensity Discharge (HID)
 Delivers more lighting per lampDelivers more lighting per lamp
 Requires longer warm-up timeRequires longer warm-up time
 FilterFilter
 Most important component of a spray booth, must be capable ofMost important component of a spray booth, must be capable of
holding and capturing all dirt, overspray, and solventholding and capturing all dirt, overspray, and solvent
 Prevents paint build-up on fans, exhaust, and release of paintPrevents paint build-up on fans, exhaust, and release of paint
particulates into the environmentparticulates into the environment

29. Paint Spray Booth Interior –Paint Spray Booth Interior –
Down Draft Spray BoothDown Draft Spray Booth
Fluorescent Lighting
Polyethylene Sheeting/
Masking Cling Film
Grates
Ceiling Air Inlet,
filters above inlets
Filters beneath grates

30. Air Intake and Filters

31. Maintain Spray Booth andMaintain Spray Booth and
ComponentsComponents
 Produces cleaner paint jobs, reduces waste, andProduces cleaner paint jobs, reduces waste, and
protects worker’s healthprotects worker’s health
 Results in lower labor costs, reduces operation costs,Results in lower labor costs, reduces operation costs,
and reduces material costsand reduces material costs
 Develop a routine maintenance schedule thatDevelop a routine maintenance schedule that
includes:includes:
 Changing filtersChanging filters
 Masking off booth surface and equipmentMasking off booth surface and equipment
 Checking paint buildup on fansChecking paint buildup on fans
 Overall good housekeepingOverall good housekeeping

32. Maintain Spray BoothMaintain Spray Booth
Manometer- check routinely for
optimum air flow
Keep booth clean
Remove dust and debris

33. Paint Waste ReductionPaint Waste Reduction
 Waste reduction equates to cost savings forWaste reduction equates to cost savings for
shopsshops
 Employee incentivesEmployee incentives
 Ask for their ideasAsk for their ideas
 Share cost savings of significant waste reductionShare cost savings of significant waste reduction
with workerswith workers
 Allow time and incentives for training refreshersAllow time and incentives for training refreshers