CHALLENGE: WIRE LUBRICATION FOR INSULATION PROCESSES
Traditional methods of applying lubrication often result in inefficient overspray and inconsistent coverage. While overspray presents its challenges, uneven application is viewed as faulty by customers and returned, or in extreme cases, recalled by the manufacturer. To avoid this possibility, excessive lubricant application was common and led to an overuse of product. This not only increased their material costs but excessive overspray on floors and equipment caused unnecessary safety risks for the manufacturing team.
SOLUTION: AUTOJET AND PULSAJET TECHNOLOGY
Spraying Systems Co.’s AutoJet® system, combined with its PulsaJet® spray nozzles, offers a fully integrated solution that addresses these challenges by delivering consistent, precise, and efficient lubrication.
- PRECISION SPRAY CONTROL(PSC) WITH AUTOJET® SYSTEM
The AutoJet system delivers remarkably accurate control over the previous lubricant application. By employing Precision Spray Control, the manufacturer can adjust the flow rate according to the speed of the wire, ensuring consistent lubrication even at varying line speeds. This advanced technology enables exact dosing that reduces lubricant consumption, decreases overspray, and optimizes the wire production process. - PULSAJET® SPRAY NOZZLES FOR ACCURATE APPLICATION
PulsaJet spray nozzles are designed to work seamlessly with the AutoJet system to deliver controlled bursts of lubricant precisely onto the wire. The high-speed pulsing capability ensures precise application to the target area while providing the flexibility to adjust spray patterns for different wire sizes and production setups.
RESULTS: ENHANCEDEFFICIENCY AND COST SAVINGS
This wire manufacturer achieved significant improvements in the finishing lubrication processes as a result of implementing Spraying Systems Co.’s AutoJet and PulsaJet technology. The benefits of precise and consistent application include increased cost savings from using less lubricant, superior product quality and improved customer satisfaction
NOZZLES
Electrically Actuated and Air Atomized PulsaJet nozzles allow for the accurate, precise, and high speed flow adjustments with air assisted atomization.
SPRAY CONTROL
The AutoJet 1750+ Spray Control Panel provided repeatable timing and oil volume.
AIR CONTROL
Optimal for liquid- and air-atomizing nozzles and applications requiring the break up of mid- to high-viscosity fluids without sacrificing spray pattern integrity.
LIQUID DELIVERY
Liquid flow is controlled by an internal, manual pressure regulator that sets the air pressure to the pressure pot.
ADAPTIVE ZONE CONTROL
In this application, zone control was not required.
QUALITY CONTROL
Precision Spray Control allows for more precise oil volume application.
CONCULSION
Spraying Systems Co.’s AutoJet systems and PulsaJet spray nozzles provide wire manufacturers with a superior solution for lubricating wires before final spooling and packaging. What began as a single test system has blossomed into an integral network of dozens of spraying systems delivering precise lubrication, enhanced production efficiency, reduced costs, and improved product quality while minimizing environmental impact.