Case Study: Top Tip for Water Tank Manufacturer

MONDAY, JUNE 10, 2019

By Kevin Coleman, Titan

Zinc coatings are known to offer the best barrier and catholic protection, which makes them excellent primers or base coats in multiple coat systems. If you’ve ever sprayed zinc for any amount of time, though, you know it’s abrasive and hard on equipment. Ray Walker, who oversees production and field painting for Phoenix Fabricators and Erectors, LLC (Avon, Indiana), has been in the business for 30 years and understands the costs associated with wear on parts, especially spray tips.

“A year ago, our Titan sales rep suggested we try their new TR1 HEA tip,” said Walker. “He sent us a few, and we tested them in our shop.” Since then, Phoenix has used the tips exclusively for spraying all zinc, both in the production shop and the field.

A manufacturer of steel water towers, Phoenix is headquartered near Indianapolis and employs about 45 full-time painters throughout the country. To ensure quality, the company controls all aspects of the production process, with in-house engineering, fabrication, foundation installation, field construction and painting crews.

Zinc is used as a primer for 95 percent of the water towers Phoenix produces. Raw steel plates are primed with zinc in the company’s production paint shop and then shipped to the field, where they are welded and erected on site. After the cleaning process is complete, the plates are touched up with more zinc and finished with epoxy and urethane coatings.

“Over the years, we’ve used every brand of high-pressure tip,” said Walker. “Our teams spray all day, every day, and these Titan tips will spray three times the material before wearing out. In the past, we had to replace tips once a month, but now they last up to three months.”

The economics of replacing tips less often can be significant, especially for an operation the size of Phoenix. Also, since the TR1 HEA tips have been shown to wear at a slower rate, users have more control longer into the life of the tip, and the film thickness will stay consistent longer.

The tips also atomize at lower pressures, producing the same flow and production level as standard airless tips at pressures as low as 1,000 PSI. This produces up to 55 percent less overspray, reducing waste since more coating is being applied to the steel. In addition, when operating at low pressures, pumps don’t have to work as hard and will spray more gallons before repacking is needed.

Learn more about the TR1 HEA tip here.

Claims or positions expressed by sponsoring authors do not necessarily reflect the views of TPC, PaintSquare or its editors. The stock image of a water tank (gettyimages/SKLA), linking from PaintSquare Daily News to this article, is for illustration purposes only and not related to the above manufacturer.

Kevin Coleman, Titan

Kevin Coleman is the market manager for High Performance Protective Coatings (HPPC) at Titan. With more than three decades of experience in the coatings and equipment industry, Coleman’s role includes managing and assisting with the design, manufacture and distribution of coatings application equipment.