ProBatch Leadership KitAutomating the Kitting Process in the Aerospace Industry

Table of Contents

I. Situation Analysis

II. Application Basics

III. Graco Solution

IV. Return on Investment for Aerospace Customer

V. Application Benefits

VI. Ordering Information and Prices

VII. Other Potential Kitting Customers

Automating the Kitting Processin the Aerospace Industry

I. Situation AnalysisCompanies that paint with less than 25gallons per day and use multiple colorsgenerally use kitting in their operation.Even though kitting is relatively easy thereis a tremendous cost associated to thismethod of mixing paints. Companies paya premium to have the luxury of mixing kitsinstead of doing the mixing themselves.

Kits consist of two (2K) or three (3K)components that are purchased inseparate cans and mixed together.

The benefit is that the proportion of eachmaterial is correct, which reduces errors inmix ratios, but the user lacks the flexibilityin how much is mixed. For instance, if atouch up job requires one pint of paint, the combination of three components may yield a total of1.25 gallons or the waste of one gallon of kitted paint.

The main components of kits consist of the following materials.

1. resin2. catalyst3. solvent

For the purpose of this application leadership kit, the aerospace industry will include aerospacemanufacturers, aerospace feeders and military bases. The aerospace industry offers thegreatest opportunities for the ProBatch system because it is an industry that requires manysmall amounts of a very expensive paint and is accustomed to using kits. It is not uncommonfor an aerospace manufacturer to waste up to 25% of their paint.

The aerospace industry has high quality standards and is closely watched by environmentalagencies, therefore, the reduction of waste is on everyone’s mind.

II. Application BasicsThe resin generally consists of a one gallon can of color, which can carry a price tag of $50 toas much as $300 per gallon. The catalyst generally consists of a one-pint can at a cost of $95per gallon. The solvent generally consists of a one-quart can at a cost of $25 per gallon.

The kitting process generates a tremendous amount of unused paint, which also comes with adisposal cost for the cans. Not to mention the premium that is paid for the smaller containers ofpaint.

a. Materials Used in the Aerospace IndustryWhen calling on an aerospace company it will be found that many different material supplierswill be supplying material. It is not uncommon to have as many as five different materialsuppliers. For instance, one company may supply the primer, another the paint for interiors,another for the landing gear and so on. A list of the main suppliers is below.

Supplier Industry Application Painted Part Typical RatioSterling Manufacturer, Feeder, Military,

Commercial AirlinesPrimer,(Urethane)

Interior,exterior,engine,fuselage

2:1

Deft Manufacturer (primarily Boeing) Primer(WaterBorne)

All 2:1:4.5

U.S. Paint Manufacturer, Feeder, Military,Commercial Airlines

Topcoat(Urethaneand epoxy)

Interior,exterior,engine,fuselage,edges

3 to 4:1

SherwinWilliams

Manufacturer, Feeder, Military,Commercial Airlines

Topcoat(Urethane)

Interior,exterior,engine,fuselage

3 to 4:1

Dexter Manufacturer, Feeder, Military,Commercial Airlines

Primer,Topcoat(Urethane)

Landing Gear 3:1:1or 3 to 4:1

Desoto Manufacturer, Feeder, Military,Commercial Airlines

Anti-stat Exterior 2 to 3:1

It is recommended that material suppliers be contacted before going into a potential aerospacecustomer in order to determine what paint is being used and if any material changes areforeseen.

Many companies still use military specification. The common military spec that is used is milspec 1011. Another interesting note is that the Sherwin Williams’ aerospace division does notsell to the military. Only the Chemical and Coatings division sells to the military. The aerospacedivision has no paint that meets mil spec 1011.

b. Customer TypeBoth the aerospace feeder and manufacturer are similar in their painting requirements andmaterial used. The main difference is that the aerospace feeder will have many more colors instock due to the fact that they supply multiple manufacturers. Some feeder plants may use upto 60 different colors in one day.

The aerospace manufacturer can use up to 30 gallons of primer each day and 30 gallons oftopcoat per day. The primers are generally 2K and the topcoats can be 2K, but 3K are morecommon. In humid environments solvent is used to increase the potlife time.

Military bases have the same needs as commercial airlines, where touchup and repainting isrequired. The important thing to know about selling to the military is that it is essential to speaktheir language. For instance, you do not want to call on the purchasing manager--in the militarythis person is called the procurement officer.

c. The Kitting EnvironmentA typical manufacturer may run two shifts and have 5 to 15 painters per paint kitchen. Theregenerally will be a paint crib attendant who will mix the batches for primer and color. Thesepainters will get batches anywhere from 4 oz. to 5 gallons, but a typical batch will be a pint orquart. The problem is that when hand mixing is done by the paint crib attendant the batch sizesare generally larger and paint is often wasted due to expired pot life from too much materialbeing mixed that amounts to at least 10% of the batches. Also, there is a delay when theproduction shift starts and the painters are waiting for the kits to be made. It is common to seepainters waiting in line for 15 to 30 minutes. The result is lost production time and unwantedsocializing. A painter will come to the paint kitchen 4 to 5 times per night.

Another problem that was discovered is that with so many different material suppliers, there arealso many different catalysts. It was found that when painters were making their own batchesfrom kits, they often used the wrong catalyst, because they did not understand that there couldbe a different catalyst for each paint. When bad parts need to be reworked it is a tremendouscost to the manufacturer in terms of lost production.

Wasted paint is expensive. Not only is the cost of the paint being incurred at a minimum of $50per gallon, but there is also a cost associated to disposing of this unused paint that can amountto as much as $1,500 per 55 gallon drum.

Paint TypeAverage

Paint CostAverage DailyPaint Waste

Average Weekly BadMixes

Primer- Urethane $50 to $60/gal. 10% 5%Primer – Deft $100/gal. 25% 5% to 10%Top Coat $50 to $300/gal. 10% 5%PTFE $200/gal. 10% 5%

Empty paint cans from kitting also is considered hazardous waste and must be disposed ofappropriately. An aerospace company is required to wash out the cans, dry it and contain it inhazardous material containers, often 55-gallon drums. These drums are then shipped tohazardous locations at a hefty fee, along with a separate drum that contains the solvent used towash out the cans. One manufacturer stated that they would have an eight month ROI on theProBatch just from the cost of eliminating the labor and cost of washing and disposing of thecans.

Every plant is reviewing their environmental emissions. The current method of recordingsolvent usage is by the amount of solvent that is left in inventory at the end of the month. Themore wasted paint, the more solvent that needs to be reported.

III. Graco Solution

The solution to this wasteful process is to use the ProBatch, electronic batch dispensing system.This weight-based product is a cost-effective solution to the kitting process. ProBatch uses ascale to measure the exact amount of material required to make the perfect mixture every time.ProBatch offers the range of dispenses from as low as 4 oz. to 5 gallons.

The system can handle up to 99 fluids, 6 maximum for automatic dispenses and 93 for manualadds. A total of 250 recipes can be programmed into the ProBatch through screen inputs orthrough PrecisionView AMR 2.0.

The typical return on investment (ROI) for the ProBatch will range from 1 to 10 months.

The benefits of the ProBatch in the aerospace industry is that it:1. Improves Paint Quality2. Reduces the Amount of Waste3. Improves Production by Reducing Painter’s Down Time4. Eliminates the use of Can Disposal5. Reduces the Overall Disposal Cost6. Frees Up Paint Crib/Kitchen Staff to Work on Other Projects/Tasks7. Keeps the Material Fresh8. Reduce VOC Costs

When the ProBatch was introduced at Raytheon Aircraft Company in Witchta, KS, they werehaving bad batches on 10% of their hand mixed kits. When they installed the ProBatch andinitially only dispensed the primer, they virtually eliminated their bad batches. The top coats thatwere not switched were still experiencing the 10% failure rate.

How to Reach the CustomerTo find the right person at an aerospace company can be tricky, but the best person to contactis as follows.

Company Best First ContactAerospace Manufacturers Research and Development

Environmental Person

Aerospace Feeders PresidentPaint Foreman/Supervisor

Commercial Airlines Research and DevelopmentEnvironmental Person

Military Procurement Officer, CorrosionOfficers (Corrosion ControlDepartment) or environmentalengineers

Focus on primer and only major colors, the ProBatch is not a tinting machine.

IV. Return on Investment for Aerospace Customer

The ProBatch system is an ROI sale. Most companies look for a return on their investmentwithin one year, which in most cases is obtainable even with the feed system. The followingROI model will help you in calculating the ROI for the customer. There are some additionalintangible selling points that also can be mentioned. They include the waste disposal cost ofliquid at up to $1,500 per 55 gallon drum, lost production time due to painters waiting for theirpaint at shift startup and breaks, and the reduced cost from eliminating the part rework from badbatches. The following ROI model looks at the savings from waste reduction associated withthrowing away unwanted paint when kits are used.

ROI Model for Replacing Kits in the Aerospace Industry:

n 6 Valve ProBatch: $15,800n Cost of Feed System: $7,500n Paint Used/Day: 10 Gallonsn Resin Price/Gallon: $90n Material Waste: 15%n Total Paint Usage/Year: $216,000n Total Waste/Year: $32,400

ROI: 8.6 months with feed system5.8 months without feed system

V. Application Benefits

Kitting Problem ProBatch BenefitMixing more paint than is requiredand discarding up to 25% of thebatch.

Only mix the material that is required.

Disposing of waste paint. Reduction of wasted paint reduces theneed for paint disposal.

Labor intensive. Allows for fewer paint crib attendants.Cleaning and disposing of emptycans that are considered hazardouswaste.

When purchasing in larger quantitiesand using fewer cans, the result is areduction of clean up time and wasteremoval.

Increased cost of material due tosmaller quantity purchases.

Kits generally are purchased in one-gallon cans or increments. By usingthe ProBatch, companies are able topurchase material in larger quantities.

Risk of using incorrect catalyst whenmultiple catalysts are required.

Many times bad batches made fromkits are a result of the wrong catalystbeing used. The ProBatch eliminatesthis problem.

Lost production time from painterswaiting for batches from kits at startof shift and breaks.

The ProBatch system significantlyreduces the time required to make abatch and will increase the productionof the painters.

Lost production time due tosocializing at paint crib while waitingfor paint.

The ProBatch dispenses at a rate ofroughly one gallon per minute and willeliminate the down time that paintershave waiting for their kits to be made atthe beginning of the shift.

More concern for pot life with largerbatches.

The ability to mix what you need whenyou need it greatly reduces the need torush jobs before the pot life of thematerial expires.

Difficult to adapt to humidity changes. Recipes can be created for variousweather conditions.

Production recording is cumbersome. ProBatch records all material usageand with PrecisionView AMR 2.0 thedata can be easily reported.

Training. Training painters on which paint andcatalyst to use is time consuming,where anybody can learn how to usethe ProBatch in 5 to 10 minutes.

VI. Ordering Information and Prices

U.S. PricesPackage Part numbers List Price Net Price3 Valve System 244440 $14,000 $9,8006 Valve System 244441 $15,800 $11,060

Canadian PricesPackage Part numbers List Price Net Price3 Valve System 244440 $20,875 $14,6156 Valve System 244441 $23,550 $16,485

VII. Other Potential Kitting Customers

Kitting Customers EnvironmentAutomotive Feeders • Solvent blending

• 2nd tier feeder (< 20 gal/day)• Manual spray

Recreational Vehicles • Touch-upSMC (Sheet MoldedComponents)

• Touch-up

Bus/Truck/TrailerManufacturers

• Touch-up

Furniture Manufacturers • Acid catalyzed material – direct coating (top coat)• High ratios (up to 50:1 ratio)• Use material supplier as a reference• MEKP (high end furniture, musical instruments,

boats)Signs • Highway signs

• Billboard frames• Company signs/exhibits

Caskets • Metal caskets• 2K materials• Shading

S o f t w a r e S o l u t i o n s

PrecisionView AMR 2.0 software option allows the user to program recipes from a desktop computer and link to other Graco products to produce consolidated reports. AMR 2.0 also easily integrates production data with other plant databases, and is compatible with ODBC and SQL-compliant applications, including Microsoft

®Excel, Word,

Access and others.

R e t u r n - o n - I n v e s t m e n tUse this exclusive Return-on-Investment analysis tool to see exactly how much your paint line currently costs you, where there is waste, and best of all, how quickly a Graco ProBatch pays for itself.

Typical Scenario Calculate Your SavingsPaint price per gallon(Typical $60/gal)

Gallons used per day(Typical 15 gal [56.78 L]/day)

Business days per year

Total paint cost per year

Total waste per year(Typical 15% per year)

Annual Paint Savings

*Actual performance may vary depending upon materials and process.

Find out how to save today!Graco ProBatch...setting new standards in electronic batch metering excellence!

Call 1-877-84GRACO (1-877-844-7226) for the Graco trained and authorized distributor nearest you.

250 days

X

=

X

X

=

X

=

X

X

=

$60

15 gal

$225,000

15%

$33,750

4 5 6

1 2 3

7 8 9

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EasyKeyTM

PrecisionMix IIPersonal ComputerPrinter PrecisionMix II 3K

ProBatch Informer

PROBATCH™

P R O V E N Q U A L I T Y . L E A D I N G T E C H N O L O G Y .

Electronic Batch Dispense System accurately dispensesmultiple-color, plural component paints

FIN

ISH

ING

ABOUT GRACO

P R O V E N Q U A L I T Y . L E A D I N G T E C H N O L O G Y .

Founded in 1926, Graco is a world leader in fluid handling systems and components. Graco productsmove, measure, control, dispense and apply a wide range of fluids and viscous materials used in vehiclelubrication, commercial and industrial settings.

The company’s success is based on its unwavering commitment to technical excellence, world-class manufacturing and unparalleled customer service. Working closely with qualified distributors, Graco offers systems, products and technology which set the quality standard in a wide range of fluid handling solutions. Graco provides equipment for spray finishing, protective coating, paint circulation, lubrication,and dispensing sealants and adhesives, along with power application equipment for the contractor industry. Graco’s ongoing investment in fluid management and control will continue to provide innovative solutions to a diverse global market.

©2001, 2004 Graco Inc. 300549 Rev. B 9/04 Printed in U.S.A. All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

Sales/Distribution/Service North AmericaIndustrial Customer Service 800-328-0211FAX 877-340-6427Industrial Product Information/Demonstration1-877-84GRACO (1-877-844-7226)FAX 612-378-3597

Graco Inc. is registered to I.S. EN ISO 9001

GRACO HEADQUARTERS

All written and visual data contained in this document are based on the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.

AMERICAS

MINNESOTAWorldwide HeadquartersGraco Inc.88-11th Avenue N.E.Minneapolis, MN 55413

MAILING ADDRESSP.O. Box 1441Minneapolis, MN 55440-1441Tel 612 623-6000Fax 612 623-6777

EUROPE

BELGIUMEuropean HeadquartersGraco N.V.Industrieterrein - Oude BundersSlakweidestraat 313630 Maasmechelen, BelgiumTel 32 89 770 700Fax 32 89 770 777

ASIA PACIFIC

JAPANGraco K.K.1-27-12 HayabuchiTsuzuki-kuYokohama City, Japan 2240025Tel 81 45 593 7300Fax 81 45 593 7301

CHINAGraco Hong Kong Ltd.Representative Office Room 118 1st FloorNo. 2 Xin Yuan BuildingNo. 509 Cao Bao RoadShanghai, P.R.China 200233Tel 86 21 649 50088Fax 86 21 649 50077

KOREAGraco Korea Inc.Choheung Bank Bldg, 4th Floor#1599, Gwanyang-Dong, Dongan-Ku Anyang-Si, Gyunggi-Do, Korea431-060Tel 82 31 476 9400 Fax 82 31 476 9801

GRACO INC.P.O. Box 1441Minneapolis, MN 55440-1441

PRO

BATC

HCall today for product information or to request a demonstration.

1.877.84GRACO (1-877-844-7226) or visit us at www.graco.com.

Finally there’s an inexpensive alternative to

the expensive kitting of small batches!

ProBatch ™

offers an EASY, ACCURATE batch

system that will REDUCE WASTE and

SAVE MONEY . ProBatch is specifically

designed for the cost-conscious individual

who uses many colors in low volume.

• Solvent-Based Paints/Catalysts

• Solvents

• Lacquers

• Primers

• Waterborne Paints/Catalysts

ProBatch ... Eliminates problems associated with hand mixing!

Easy recipe setup

Easy to select dispense recipe and amount

1

2

3

4

Four easy steps to set up and operate the ProBatch system.

Part No. 244441Floor model with 45º tilt screen

Easy to MaintainPull-out drawer feature allows easy cleaning of internal components.

EasyKey™ PadProvides user-friendly menunavigation and data input.

AccurateHigh-resolution, weight-based 50 lb (22.68 kg) scale foraccurate dispensing.

VersatileAdjustable dispensepoint allows dispensing from a pint-size containerto up to a 5 gallon(18.93 liter)container.

FloSync™ Controller Tracks and adjusts to fluid viscosity for faster and more accurate dispenses.

Recipe: 12

Amount: 10.0 lbs

ID# 1111

Run Last Total All Totals Alarms

Recipe: 12 Step: 1

Fluid#: 3

Step Target: 1.00

Step Actual: .50

Dispensing

ID#: 1111

Batch Target17.00

Batch Actual:.50

lbs

Dispense CompleteBatch Target: 17.00 Batch Actual: 17.00

ID#: 1111

lbs.

Recipe: 12

Step: 1 2 3 4 5 6

Fluid#: 3 42 27 0 2 6

Target: 1.0 3.0 6.0 3.0 3.0 4.0

Actual: 1.0 3.0 5.99 3.0 3.01 4.0

% 0 0 -.16 0 +.33 0

Remove container to dispense again.

Recipe#: 12

Step Fluid# Parts (by weight) 1 1 1 2 2 2 3 0 0 4 0 0 5 0 0 6 0 0

If Fluid#=0, Parts=pause in minutes/10

System Scale Fluids Recipes

• Program up to 250 recipes

• 99-fluid capacity

• Dispenses batches as small as 4 ounces

• Dispenses one to six dedicated fluids

• Centralized dispense of fluids into a cup gunor 5-gallon [18.93 liter] container

• Intrinsically safe

• Manual-Add features

• Compatible with Graco’sPrecisionView™ AMR 2.0 software

• Floor model has 45° tilt screen for easy viewing

• Sliding scale for manual-add

• Adjustable dispense positions reduce splash

• Revolutionary cascading pressure system for fast, accurate dispenses

F e a t u r e s

Package complete – just add feed system,

current, air and electricity.Monitor Dispense

Batch total summary for ratio assurance

K e y A p p l i c a t i o n s

PA

RT

NO

. 2

44

44

1

C o m p a t i b l e F l u i d s

E a s y I n s t a l l a t i o n

FinishingAerospace

Automotive Feeding

Commercial Airlines

Furniture

Military

Trailers

Signs

Touch UpAutomotive

Farm & Construction

Truck & Bus

Recreational Vehicles

GeneralAny 2 or 3-componentpaint application

Industrial

Any application with multiple colors usingless than 25 gallons (94.63 liters) per day

Technical Specifications

Power RequirementsElectrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85-265 VAC .25 amp maximum

50 or 60 HzPneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85-120 psi @ 1/4 cfm maximum

filtered to 10 micron

Material RequirementsNumber of Fluids (Total of 99 fluids):

Automatic Dispense: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 fluids maximumManual Dispense: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 fluids

Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 to 2.0Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 to 2000 cps

Dispense RangesAmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 oz (118 grams) to 5 gallons (18.94 liters)Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 1% to 3%Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/8 to 2 gpm (.47 to 7.5 lpm)

Scale DataCapacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 lbs (22.7 k) or 5 gallons (20 liters)Deck Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 in. (30.5 cm) x 12 in. (30.5 cm)

Container SizesHeight maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 in. (45.7 cm)Diameter maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 in. (30.5 cm)Diameter minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 in. (6.35 cm) for multi-valve dispenses

RecipesQuantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250Pause times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 99 minutesPause steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 maximum

SystemWeight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 lbs (56.7 kg)Height (fully extended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.5 in. (113 cm)Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 in. (56.4 cm)Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.1 in. (66.3 cm)Fluid working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 psi (17.3 bar)

PortingFluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 in. (.95 cm) npsm(f)Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 in. (.635 cm) npt

Fluid Valves3 valve system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) 1/8 in. (.32 cm), (2) 1/4 in. (.635 cm)6 valve system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) 1/8 in. (.32 cm), (4) 1/4 in. (.635 cm)

ApprovalsETLul, ETLc, ETLis

©2001 Graco Inc. Form No. 325016 Rev. A 3/01 Printed in the U.S.A.All data in this document is based on the latest product information available at the time of publication. Gracoreserves the right to make changes at any time without notice.

Bulk�Tank

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EasyKeyTM

ProBatch InstallationConfiguration

325016B SS ProBatch 6/7/05 9:25 AM Page 1

ProBatch™ Product Information

Ordering Information1. Select a ProBatch Unit

244440 ProBatch 3-FluidThree valves for up to three fluidsOne 1/8 in. valve and two 1/4 in. valves

244441 ProBatch 6-FluidSix valves for up to six fluidsTwo 1/8 in. valves and four 1/4 in. valves

2. Distributor-Supplied Feed SystemTypical Feed Packages May Include:

5-15 gal (18.9-56.8 l) pressure potsHusky Diaphragm PumpPiston Pump

3. AccessoriesPrecisionView AMR 2.0243377 Single station license243378 Up to 5 station license243379 Up to 31 station license

244534 ProBatch Barrier Kit with AMR 2.0For use in hazardous areas

115769 500 ft. (152 m) Beldon 9841 Network Cable115770 1,000 ft. (304 m) Beldon 9841 Network Cable116542 25 lb. (11.3 kg) Calibration Weight

Official weight for calibration of the scale197502 Control Box Adapter

Allows the operator to view the screen at a 45º angle239873 Printer Kit

Includes 113774 printer and 192491 25 ft (7.6 m) power cable514037 Printer Paper244509 Printer Barrier Kit

For use when ProBatch is in a hazardous area197902 Paint Shield Membrane

This clear membrane comes in a pack of 10 and protects the screen from fluids

4. Upgrade Kits244382 1/8 in. (3 mm) Valve Needle and Nozzle244383 1/4 in. (6.3 mm) Valve Needle and Nozzle 244384 Stainless Steel Valve Needle and Nozzle244792 Dispense Valve Assembly Kit/Less Valves

- Regulator, mounting hardware, tubing, fittings

5. Repair Kit244385 Needle Nozzle Kit Accessory: 1/8 in. (3 mm)244386 Needle Nozzle Kit Accessory: 1/4 in. (6.3 mm)244387 Needle Nozzle Kit Accessory: Stainless Steel

Note: For fluids with viscosity greater than 2,000 cps, the ProBatch regulators can be bypassed and feed systems connected directly to the valves.

PrecisionView AMR 2.0

Control Box Adapter197502

Calibration Weight116542

Printer113774

325016B SS ProBatch 6/7/05 9:25 AM Page 2

Plural Component Product Selector Guide

# of Colors Gal (L)/Day DescriptionProduct 1 2-3 4+ <25(95) >25(95)

ProMix™ Easy X X X The ProMix Easy entry-level sprayer replaces manualpremixing of plural component materials.

ProMix™ II X X X X X The ProMix II with Gun FlushBox eliminates solvent andpaint waste from purgingmanual applications.

PrecisionMix® II X X X The PrecisionMix II electronic proportioner provides on-demand ratioproportioning and control.

PrecisionMix II 3K X X X The PrecisionMix II 3Kelectronic proportionerreplaces manual premixingof solvent in plural component materials.

ProBatch™ X X X The ProBatch electronicbatch dispense system dispenses multiple batchesper day with excellent ratioassurance.

ProMix Easy ProBatch

325016B SS ProBatch 6/7/05 9:25 AM Page 3

PrecisionMix II & PrecisionMix II 3K

Plural Component Product Performance Guide

ProBatch ProMix Easy ProMix II PrecisionMix II PrecisionMix II 3K

Ratio Assurance 1% 1-5% 1% 1% 1%

Ratio Range 1:99 1:1 - 3:1 1:1 - 30:1 0.6:1 - 30:1 0.6:1:0.6 - 20:1:10

Flow Rate (cc/min) 200-4000 3800 3800 3800 2000

Maximum Pressure 250 psi 400 psi 4000 psi 3000 3000(17.2 bar) (27 bar) (276 bar) (207 bar) (207 bar)

Diagnostics (online) X X X X

Patented Mixing Technology X X X X

Intrinsic Safe (option) X X X X X

Gun Flush Box (option) X X X

Pot Life Alarms X X X X

Automatic Flush X X X

Printer (option) X X X X

Network (option) X X X

Recipe Control X X X x

Automatic Color Change (option) X X

Flow Control (option) X X

Automatic Solvent Reduction X

ProMix II

325016B SS ProBatch 6/7/05 9:25 AM Page 4

In an effort to reduce abottleneck in an area of theirWichita facility where aircraftparts and components arepainted, Raytheon AircraftCompany - a world leader inbusiness and special missionaircraft - installed a batchdispense system to accuratelydispense a two-componentprimer. Almost immediately,the new system significantlyreduced the bottleneck,improved quality and reducedwaste.

Prior to installing thebatch dispense system, thetwo-component primer andplural component topcoatswere hand-mixed by the PaintDepartment’s crib managers(CM). To keep pace withproduction, the first shift CMhad to arrive an hour before

the painters started work tohand-mix the materials in 5-gallon batches. He would thenladle the paint into pint, quartand gallon containers so whenthe painters arrived, they couldget right to work. As the dayprogressed, he would hand-mixadditional batches and ladlethese out to the painters asthey needed more material.Typically, the CM filledbetween 120 – 140 requestseach shift.

The primer and topcoatwere metered in these smallamounts because the materialhas a short pot life. On hotdays, the metered material cancure within 90 minutes. Thematerial that isn’t sprayedwithin this time period has tobe thrown away.

“There could be 7 – 8

painters waiting for material atone time,” says J.D. Mavity,Section Manager of the thePaint/Process Department. “Itwasn’t a very efficient process.Furthermore, if the CM wasrushing to keep up with a lineof painters all needingmaterial, the chance ofinaccurately hand-mixing thetwo-component paintincreased. If the material wasoff-ratio, it could result in apoor cure rate or in extremecases, rework.”

“In addition to being time-consuming and inaccurate, theprocess was messy and resultedin a high amount of wastedpaint,” adds Larry Keefer,Process Engineer. “We needed amore productive, cost efficientsystem.”

Raytheon installed a GracoProBatch™ Batch DispenseSystem. The electronic systemprovides a cost effective andenvironmentally compliantsolution for dispensing batchesof plural component materials.The system allows Raytheon’spainters to quickly dispensevariable batch sizes as small asfour ounces to meet changingjob requirements with high on-ratio assurance. The paintersimply places his container onthe scale, enters the amount ofmaterial he needs and presses abutton to start the dispense

PROBATCH™ ELIMINATESBOTTLENECK AT RAYTHEON

Raytheon Aircraft Company usesthe Graco ProBatch™ to dispense atwo-component epoxy primer intopint, quart and gallon containers,reducing waste and downtime.

FI

NI

SH

IN

G

CUSTOMERRaytheon Aircraft Co.,Wichita, KS

APPLICATIONPainting aircraft parts& components

PROBLEMHand-mixing caused a bottleneck andexcessive waste

SOLUTIONGraco ProBatch™Batch DispenseSystem

RESULTSBottleneck eliminatedand waste reducedsignificantly

APP

LICA

TIO

N

Raytheon QE 8/16/01 10:16 AM Page 1

process.It’s simple to operate. “When we

get a new painter, I take him over tothe system and show him how itworks,” says second shift CM MaconMcMillan Jr. “In five minutes he knowshow it operates and he can dispense hisown material.”

The easy-to-use computer-drivensystem links pre-programmed recipeswith weight-based metering todispense base and catalyst from 10-gallon pressure pots into a single batchcontainer. The controller can store theparameters for up to 99 fluids and 250recipes.

When Raytheon received theProBatch system, they decided to use itto batch their two-component epoxyprimer. “We spray over 225,000 parts inthis area every year and every part isprimed. This material accounts for over50 percent of our paint usage. It wasjust logical to see what effect it wouldhave on reducing this bottleneck.”

Now painters can step up to theProBatch and dispense their ownprimer, in the amounts they need. It’sfast, clean, and accurate.

“It’s so convenient,” says Mavity.“The painter dispenses his primer andgets right back to work. There’s nowaiting in line. No holdups. We’veincreased production by about 10%.And since we began using the systemwe haven’t had a single off-ratioincident.”

The ProBatch system also reducedwaste. “During the day, I would get ridof mixed material that was starting tocure,” says McMillan. “At the end of myshift I had to get rid of the unusedprimer and paint in my mixing pails. Typically, I threw out 3-5 gallons ofmixed primer and paint every night.Since the ProBatch was installed, we’vevirtually eliminated primer wastebecause the two-component materialsaren’t mixed until the painter dispensesthe base and catalyst into a containerplaced beneath the system’s dispensevalves.”

The ProBatch has worked so wellthat Mavity hope to install a secondProBatch to meter their two primarytopcoat colors — a glossy white, highsolids epoxy and a black high solidsurethane. Each material uses a differentcatalyst so they would need a ProBatchthat could dispense 4 differentmaterials, plus another dispense valvefor solvent. This isn’t a problem becausethe ProBatch system is available witheither three or six dispense valves. “Theprimer and two primary topcoat colorsaccount for 85 percent of the materialused in this area,” says Mavity. “If wehad a second system, we’d completelyeliminate our paint room bottleneck, aswell as increase quality and reduce

waste.”The CMs from both shifts agree

that the ProBatch has made their jobeasier. “It’s not as hectic and I don’thave a line of painters waiting for me to mix up a batch of paint for themanymore,” says McMillan. “It allowsme to do a better job on my other

chores.” •

For additional product information or thename of a local authorized Gracodistributor, call toll free 877-844-7226 inthe U.S.A. In Europe: (32) 89 770 700

©2001 Graco Inc. Form 320434A 8/01Printed in the USA

Painters use Graco’s Delta™ spray guns to apply the primer and topcoat colors. They use theProBatch to accurately dispense the plural component primer which the painters spray on allparts and components.

Raytheon QE 8/16/01 10:17 AM Page 2