Paintshop Basics

Introduction to the Paintshop

and its products

Paintshop Basics

What is a Paint Shop?

The Paint Shop

is a specialized
area in the
production of an
automobile

Paintshop Basics

What Does a Paint Shop Do?

The
The Paint
Paint Shop
Shop
Receives
Receives the
the
Body-in-White
Body-in-White and
and
Returns
Returns aa Finished
Finished
Painted
Painted Body
Body to
to
the
the Trim
Trim and
and
Assembly
Assembly Areas
Areas

To
To Produce
Produce the
the
Protective
Protective Paint
Paint
Finish
Finish Seen
Seen on
on an
an
Automobile,
Automobile,
Several
Several Layers
Layers are
are
Applied
Applied

Paintshop Basics

Body-in-White

Bare steelbody Body-in-white

Paintshop Basics

Phosphate Layer

Chemically developed surface coating

Paintshop Basics

Electrocoating layer

Corrosion-protection-Paint coating

Paintshop Basics

Primer Layer

Primer paint coating

Paintshop Basics

Basecoat Layer

Colored paint coating

Paintshop Basics

Clearcoat Layer

Clear paint coating for protection against elements

Paintshop Basics

Paintshop Basics

How is a process, how chart, layout developed?

Innovation

Experience
Know how

Paint
suppliers

Durr

Budget

Design
parameters
Supplier

Chemistry

Client

Preferred
methods
Space
available

Paintshop Basics

Conveyors

Monorail
Skid
Ro-dip

Paintshop Basics

Bodies are Moved Through the Paint

Shop and Between Floors with Conveyors

Paintshop Basics

Overview of a
Phosphate System
Also called
pretreatment system

Paintshop Basics

What Is Phosphate?

Phosphate is a chemically
developed surface coating

It helps shield metal from air,

moisture, etc.

This increases corrosion

resistance

And simultaneously provides a

roughed-up surface for the next
paint layer to adhere to.

Paintshop Basics

What does a Phospathe System do?

It throughly rinses, washes nad clean the body

It deposits a phosphate coating on the body
Improves paint adhesion
Prevents underfilm corrosion
Helps shield metal from air and moisture

Paintshop Basics

Remember, the reason behind the

Phosphate system is to prepare the body
for subsequent paint layers.
Some of the stages in the Phosphate
system are:
Degreasing
Rinsing (various)
Activation
Zinc Phosphate
Passivation

Paintshop Basics

Ventilation System
The phosphate enclosure air flow is negative in an
attempt to contain the steam and chemicals
generated in the process.
Exhaust Air
Supply
Fan
Supply Air
Paint
Shop
Air

Phosphate Enclosure

Paint
Shop
Air

Paintshop Basics

Overview of an
Electro Coating System
or E-coat System

Paintshop Basics

Why do we have an E-Coat Process?

Electrocoating provides corrosion
protection to the vehicle.
A uniform, protective coating is
applied to all the paint vehicle parts.

Paintshop Basics

How is E-Coat Paint Applied?

+
+
+ ++++ + + - ++
The negatively charged
vehicle is dipped into a tank
of positively charged paint.

Paintshop Basics

The Electrochemical Reaction

Since opposites attract, the positively charged
paint is drawn to the negatively charged body.
This process continues until a continuous and
even film coats the entire surface of the body.
The process stops itself when the film is almost
equal on all its surfaces.

Paintshop Basics

The E-Coat System not only consists of the E-Coat

Paint, but successive stages to rinse excess paint
off of the bodies.

These stages can consist of:

Cream Coat Rinses
Ultrafiltrate Dips and Sprays
R.O. Water Dips and Sprays
Deionized Water Sprays

Typical spray ring

configuration

Paintshop Basics

Overview of a Spray Booth

Paintshop Basics

Spraybooth Cross Section

supply

exhaust

plenum
enclosure
scrubber

Five major
components

Paintshop Basics

What is a Spray Booth?

Spray Booths have been engineered and installed
as separate enclosures within the Paint Shop
For the purpose of applying paints to the body:
Prime Coat
Base Coat
Clear Coat

Paintshop Basics

The application of the various paint

layers requires that the exact
environmental conditions be
maintained in order to achieve
maximum quality

Paintshop Basics

SPRYBOOTH FILTRATION

AIR FLOW
A Filtered Environment is required to Minimize Dirt
and Dust in the spray Booth

Paintshop Basics

Containment of Paint
Overspray

Paintshop Basics

Maintaining
Specific Temperature
and Humidity

24 C - 1C
75% RH - 5%RH

Paintshop Basics

Air Flow Balance Zone to

Zone
and Air Flow Down Drafts

Paintshop Basics

Isolation of the
Spraying Process

from the Remainder

of the Plant

Paintshop Basics

Different types of operations occur in

the Spray Booth.
Each operation takes place in an area
called a zone.
Some zones are:
a blow off or feather duster zone
a solvent / water wipe zone
a tack-off zone
manual paint application zones
automatic paint application zones
flash-off zones

Paintshop Basics

Supply air for the Spray Booth comes from

air supply houses located on a mezzanine or
penthouse level above the booth

General Assembly
Filter-unit F5

Cooling- / Heating section

Humidifier

Filter-unit:
For Air cleaning
Cooling-/heatingsection:
For the temperature of
the air in the region of
the paint window
Humidifier:
for the
conditioning of the
air to the
necessary
humidity
Fan:
For intake of the air

Silencer:
to adsorb sound
Filter-unit F7

Fan
Sound absorber

Paintshop Basics

The supply air is ducted to

various zone plenums and
introduced into the booth through
distribution filter media which
makes up the booth ceiling.

Paintshop Basics

The paint laden air is then pulled

down the throat of the scrubber.

Paintshop Basics

Scrubber System
Booth Air Downdraft

Scrubber Pressure Drop is

Adjusted to Achieve Desired
Efficiency

Paint Laden Air

WATER DISTRIBUTION TROUGH

Scrubbed

Air Out

FLOOD PAN

FLOOD PAN

SCRUBBER

BAFFLE

Cross-Section of

WATER DISTRIBUTION TROUGH

WATER RETURN
TROUGH

Drr Mini-Baffle

Paint Solid Laden Water

Paint
particles
collide with
the water
particles

Paintshop Basics

Supporting Cast:
Sludge System
Paint Circulation System
Humidification System
Powder Paint System
Building HVAC System

Paintshop Basics

Filterhouse

Spraybooth

Air From the

Spray Booth

Regenerative
Thermal
Oxidizer (RTO)

Carbon Rotor

Paintshop Basics

Overview of an Oven

Paintshop Basics

Why are There Ovens in

the Paint Shop?
Ovens heat all parts of the job
uniformly to the target temperature
Ovens cause the paint to cure into
a hard, dirt-free finish
*Ovens are a critical component of

modern Paint Shops

Paintshop Basics

What is a
"Conventional" Oven?
Radiant
Bring-Up
Zones

WORK

Convection
Heat-Up
Zones

Convection
Hold
Zones

Paintshop Basics

Purpose of the
Bring-Up Radiant Zones

Add Heat to the Work to

Bring all Parts up to the
Target Temperature

Add Heat in a Uniform,

Controlled and Dirt-Free
Fashion

Paintshop Basics

Purpose of the Heat-Up Convection Zones

Add Heat to Low Heavy

Metal Components of the
Job

Paintshop Basics

Purpose of the Hold Convection Zones

Maintain Temperature on
the body
At Time Specified for Proper
Cure

Historically Circulating air

is Used
Indirect Fired Heaters

Paintshop Basics

Q: What Does a Heater Do?

A: The Heater Supplies Heated Air to the Oven

1- Positioned near the oven, the heater uses a natural
gas burner to heat air (either directly or indirectly).
2- Heated air is supplied to Oven to maintain
specified temperature.
Oven

Duct
Flexible
Connection
22

Heater

11

Paintshop Basics

Oven heaters
What Do We Mean By
"Direct-Fired"
or "Indirect-Fired"?

Paintshop Basics

Direct-Fired Heater Operation

RETURN
DUCT

SUPPLY
DUCT

RECIRC.
FAN

FRESH
AIR

COMBUSTION
BLOWER
FRESH AIR

EXHAUST TO
ATMOSPHERE

Paintshop Basics

Indirect-Fired Heater Operation

SUPPLY
DUCT

RETURN
DUCT

RECIRC
FAN

FRESH
AIR

COMBUSTION
BLOWER
FRESH AIR

Air through
the Oven

Paintshop Basics

Oven

Regenerative
Thermal
Oxidizer (RTO)

Paintshop Basics

Typical Project as it Flows Through

the Company
1998

1999

2000

J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
Order Received
Engineering and P/E
Site Work & Building
Installation
Start-Up / Facility Launch
Turn Over to Production

Where are you involved?

Paintshop Basics

Paintshop Basics

Turnkey Paintshop
Site
Preparation

Manufacturing

Building
Erection

Process
Installation

Launch

SOP

Facility Support
Services

Paintshop Basics

Product Line
Facility / Layout

Phos/EC

Ovens

Booths

Paint
Circ / Piping

Paintshop Basics

Product Line
Controls

Environmental

Application
Equipment

Robotics

Conveyors/
Material Handling