Customer, Challenge & Risks
Our customer was an Engineer from a material supplier to a global tire manufacturer. She was working with tire manufacturers facing the common challenge of tires sticking to the bladder during the curing process. She needed a way to demonstrate their mold release product; if correctly applied to the tire, it was superior to the competition. She called on Pioneer because we were already well known as the spraying experts in the tire industry. She wanted a portable machine that could be put into a truck and taken on-site to a tire manufacturing plant, power applied, tires sprayed, cured, and material usage and spray characteristics tested and observed.
She was familiar with our model HTS100i manually loaded inside tire spray booth, having seen one at a local tire manufacturer. However, she wanted to test both inside and outside mold release materials and asked if we could add outside spray guns.
Another challenge was that this unit needed to be a portable machine that could be easily moved from plant to plant so it required a self-contained exhaust filtration system. It also needed to be cleaned between demonstrations quickly and easily.
Thankfully, both She and all her customers were already familiar with Pioneer Industrial Systems since they were already using our high-speed automatic dial spray machines. Our director of sales took the lead on this project and invited her to our shop for a demonstration of an HTS100i on our floor, where we worked to understand further the challenges, constraints, and requirements of the system she was looking to build.
Our engineers have been working with the tire industry since the late 1980s, so we understood the importance of keeping the mold release inside the tire and what a mess the overspray could make. Using our history and knowledge of our Precision Fluid Delivery System and our basic low-cost Pressure Pot solution we worked to provide a lower cost non-servo controlled, but variable controlled pressure fluid delivery system where we could still vary the spray gun fan width, atomizing pressure, and fluid pot pressure and created a dual system for both inside and outside spray.
We also used our history of spray booth projects to offer a three-sided open face spray booth that included many other benefits. We had a excellent starting point that not only included a fully sealed bottom with removable access grating for cleaning but a drain port for cleaning of the portable booth, and the booth was wash down compatible. We worked with a vendor to incorporate the correct CFM and filtration to help minimize and collect any overspray in a small package that could be mounted to the portable spray unit. After providing the customer with a proposal that included our prior experience with tire spraying technology and collection, along with low-cost and portability, the unit was approved, and a purchase order was issued.
Pioneer started its defined Machine Building Process. This process involved detailed engineering kickoffs, where we worked closely with the customer on getting signed approvals for mechanical layouts, electrical schematics, and programming structure. As the project came together on the floor, consistent updates were sent to the customer. Since this was a simple manual load automatic spray machine, the customer asked for a video of the machine running a few spray cycles on different size tires. After the customer runoff, the machine was packaged and shipped to the customer, where it is currently being used for in-plant demonstrations at various tire plants across the United States.
The customer was given machine drawings, a detailed machine manual, the latest copies of the PLC program, and a spare parts list.
Outcomes of Success
Overall, the project was very successful. The system was shipped and is continuously being used by the customer for demonstration purposes. Both inside and outside lubes can be sprayed onto tires of various sizes. The spray was contained with minimal to no overspray getting outside of the spray booth.
The engineer was involved throughout the project, so she was always aware of status, any obstacles, and felt comfortable through the entire design and build process. Mold release consumption was controllable and containable, which was a substantial cost savings in both material consumption and labor involved. The primary purpose of developing a portable demonstration unit was achieved.
The machine performed quite well as a manual loaded automatic spray booth that was portable, could be moved around as needed, allowed for both inside and or outside spray, and allowed the customer to demonstrate their product to various tire manufacturers.
Horizontal Tire Spraying (Inside & Outside Spray)
Horizontal Tire Spray Advantages
- Manual setup
- Low cost manual load/unload
- Manual fluid regulator
- Manual spray gun adjustment
- Paint entire 360 degree inside and outside
- Spray based on timer
- Easy access maintenance
- Replaceable filters
- Quick change spray guns
- Ease of installation
- Spare parts
HTS100io Feature Highlights
Adjustable timer to allow tire to get up to speed prior to painting. Potentiometer to adjust tire rotation speed. Push button starts & keeps the tire rotating. Tire stops when the button is released.
Knurled rollers to provide grip.
Quick change spray gun & manually adjustable positioning of the spray gun.
Manually adjustable regulators for Fan and Atom air pressures.
5 gallon Stainless Pressure Pots.
Wet mist collector with Secondary HEPA filter.
|Model “HTS100io” Specifications|
|Bead Diameter||12″ – 24″||305– 610mm|
|Tire Width (bead-bead)||6″ – 24”||152– 610mm|
|Tire OD Diameter||16″ – 36”||406– 915mm|
|Max Tire Weight||85lbs||38.5kg|
|Inside Tire Spray||360 degrees|
|Cycle Time (tph)||Approximately 180|
|Cycle Time (tpd)||Approximately 4,320|
|Tire Measurement||N/A – manually adjusted by operator|
|Bar Code Reader||Optional|
|Spray Gun||Quick change manifolds|
|Spray Gun Pattern||Variable fan manually adjustable|
|Fluid Delivery||5 gallon Pressure Pots|
|Atomizing Air||Variable manually adjustable control|
|Tire lube||Water based system|
|Water Purge||Not Standard|
|Infeed conveyor||N/A—Manual load/unload|
|Electrical Service Req’d||480v/3ph/30amp or 380V|
|Air Service Req’d||80psi @ 3/4″inlet|
|Water Service Req’d||NONE|
|Machine footprint||5′ x 5’-4”|
|Exhaust Fan||1 hp||700 cfm|
|Dual Filters||Secondary HEPA filter|
|Backdraft booth||Powder Coated Steel|
Pioneer’s HTS Green Tire Sprayer is ideal for Radial or Bias-Ply Passenger, Utility, Trailer, and AG Tires.
Our pressure pot spray system provides the low cost solution you need for spraying green tires.