Air Quality Control for the Automotive Painting Process

Avoid paint defects and expensive rework


Controlling Air Quality of Paint Lines

Managing an automotive paint line is challenging. The smallest factors can have serious consequences. Air quality is critical to every step of the process in a paint shop. Contaminated air can lead to expensive rework and even shut-downs of the line. It can significantly impact the “First-time Through Rate” and the overall production schedule of a vehicle.

AAF offers complete solutions for improving the air quality in painting lines, painting booths and drying ovens, both for the system supply air and exhaust air, including the efficient handling of paint overspray.

Filter Elements

Housings and Equipment

Panel Filters

Our panel filters are ideal for protecting more expensive secondary air filters from premature dust loading and replacement. As primary filters, they also help reduce HVAC maintenance costs by preventing unnecessary dust build-up on coils, fans and duct work.

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Pocket Filters

Our pocket filters (DriPak SX, NX and GX)  have the highest dust holding capacity, with optimised pressure drop behaviour for high performance, which is crucial for automotive paint booths.

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Compact Filters

Our Compact Filters have a high DHC. Higher dust holding capacity results in less filter changes and an extended service life, thus reducing replacement costs.

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Media Pads and Rolls

Our AmerTex media pads have filter media with an optimized blend of synthetic fibres. This filter is designed for filtration of air ducts and fans in paint spray booths and for central air handling systems.

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High Temperature Filters

The VariCel HT filter is designed for use in drying ovens. Made of sturdy aluminized steel, this filter has a maximum continuous operating temperature of 385 °C. Aluminized steel is used because it does not spall or flake at elevated temperatures.

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Gas Phase Media

Our engineered gas removal chemical media is designed to remove a broad range of contaminants.

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TranspAIRency service

AAF introduces an air quality and filter systems optimization program for automotive manufacturing processes.

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Gas Phase Cassettes

The patent-pending enhanced media utilization design eliminates the "nose cavity" typically created by legacy cassettes. Nose cavities "cocoon" up to 30% of the chemical media, keeping it isolated from airflow contact at all times during the life of the cassette. SAAF Cassettes are the only cassettes to utilize 92% of all chemical media in the cassette, outperforming legacy cassettes by 25%.

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AIVY RCTM

AAF’s AIVY RCTM is a modular cartridge dry dust collector highly efficient in a wide range of air flows: from 4,000m3/h up to 125,000m3/h. Adaptable and configurable, it allows increasing the number of cartridges depending on the filtration needs by simply adding additional modules.

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AIVY CompactTM

AIVY CompactTM is a cartridge dry dust collector that can efficiently handle a wide range of flows: between 1,000m3/h and 20,000m3/h.

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RotoClone® LVN

RotoClone® LVN is a compact and easy to use wet dust collector, specially designed to meet the needs of metalworking industries when filtering small applications under 4500m3/h.

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PulsePak® Prime

RotoClone® LVN is a compact and easy to use wet dust collector, specially designed to meet the needs of metalworking industries when filtering small applications under 4500m3/h.

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AIVY RCTM

AAF’s AIVY RCTM is a modular cartridge dry dust collector highly efficient in a wide range of air flows: from 4,000m3/h up to 125,000m3/h. Adaptable and configurable, it allows increasing the number of cartridges depending on the filtration needs by simply adding additional modules.

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AIVY CompactTM

AIVY CompactTM is a cartridge dry dust collector that can efficiently handle a wide range of flows: between 1,000m3/h and 20,000m3/h.

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SAAF™ Side Access Housings

The SAAF Side Access Housings (SAH) are self-contained, double-walled units that hold particulate filters and gas-phase cassettes for a total clean air solution. They are designed for a wide range of flexibility in installation. The patent-pending SAAF Seal locks cassettes and filters in place to prevent bypass and wasted energy.

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Once contaminated air particles cause a defect on a freshly painted surface, a Loss of Control Event is reached. This is the point at which costly rework is unavoidable.

There are significant costs associated with managing risks and detecting defects. Even when the most comprehensive precautions are taken, failures occur. Actual detection efficiency rates of trained human operators range from 80% to 90%. When robots are used to fill the role of human operators, detection efficiency rates increase to approximately 96%.

Potential Causes of Defects Leading to Rework:

  • Ambient dust or process dust
  • Human hair
  • Textile fibres
  • Contaminants, such as silicone or PVC particles
  • Human error
  • Process error

Required rework causes productivity to suffer:

  • Longer production schedules
  • Loss of profits due to add-on-processing
  • Negative impact on Key Performance Indicators
  • Increased operating costs for paint line

 

Managing air quality for painting processes is critical to maintaining a fluid supply chain. Eliminating airborne dust contamination is essential to preventing failures which halt production, affecting both the upstream and downstream supply chain.

The first step in controlling air quality is installation of appropriate filters for all stages of the paint process. Early detection and effective management of contamination risks are key to minimizing production disturbances and reducing costs.

The paint shop is the most energy intensive step of car manufacturing. A full 75% of the total energy required for the process is used in the operation of the paint shop’s ovens and spray booths. To achieve the air quality required for optimal surface treatment results, large quantities of air are temperature treated and moved.

Paint shop operation teams need the support of a trusted on-site advisor who can perform air filtration audits, diagnostics, and continuous improvement to ensure the most optimal effective solution for cost savings and risk reduction.

We do this by providing a consultative and technical approach to understanding your complete air filtration needs, application, and business goals, to optimize your performance and lower your total cost of ownership.

Filter Elements

Housings and Equipment

Services

Rendering 1 Surface Treatment

Filter Mats

This fibreglass filter media is designed for filtration for protection of air ducts, fans and engines in paint shops.

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TranspAIRency service

AAF introduces an air quality and filter systems optimization program for automotive manufacturing processes.

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AmerGlas Paintstop

AmerGlas Paintstop is designed for filtration for protection of air ducts, fans and engines in paint shops.

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Filter Elements

Housings and Equipment

Services

Rendering 2 Surface Treatment

HT Filters

Our HT Compact Filters are designed to improve air quality in hot air systems, such as paint drying lines, with a great energy savings level and attractive life cycle cost.

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TranspAIRency service

AAF introduces an air quality and filter systems optimization program for automotive manufacturing processes.

Click here to learn more

Filter Elements

Housings and Equipment

Services

Rendering 3 Surface Treatment

Pocket Filters

Our pocket filters have the highest dust holding capacity, with optimised pressure drop behaviour for high performance, which is crucial for automotive paint booths.

Click here to learn more

TranspAIRency service

AAF introduces an air quality and filter systems optimization program for automotive manufacturing processes.

Click here to learn more

Compact Filters

Our Compact Filters have a high DHC. Higher dust holding capacity results in less filter changes and an extended service life, thus reducing replacement costs.

Click here to learn more

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