Volume 5 www.sonicairsystems.com Issue 4

Coating Control Application Customer: Certainteed Building Products - NC, USA Application: A major manufacturer of residential and commercial building materials was looking to improve their coating control of their composite material boards. They run two types of boards, a cedar board with molded impressions and the other is a standard flat board. Their goal was to control the thickness of the excess water-based paint applied to the boards. Their process consists of (6) 10”W boards traveling horizontally across a 60”W roller conveyor with a line speed of 78FPM. Previous Method: Their existing process involved smoothing out the excess paint using a rotating wire brush. The brush had it’s advantages in that it helped to impregnate the board with paint, which allowed for a uniform coat with minimal streaking or spotting. But the continual maintenance and replacement costs drove them to look at a viable alternative that could achieve the same quality. The Sonic “Engineered” Solution: The manufacturer contacted Sonic Air Systems because Certainteed uses Sonic in other plants. For this application, Sonic offers a blow off system for removing and smoothing coatings, with the “Coating Control” air knife. Sonic’s Coating Control design eliminates streaking caused by standard air knives to ensure the highest quality surface finish. One of the concerns with their current method is maintenance. They did not wish to place another piece of equipment on the line that would have to be monitored or difficult to clean. The Sonic “Engineered” Solution (cont.): Sonic Air looked to replace the rotating wire brushes with a laminar air flow that would both remove the excess paint while providing a smooth finish. The impact velocity for an application such as this is very important, as well as the attack angle and the distance to the product. With Sonic’s expertise it didn’t take much time to come up with the right combination of all three to achieve the desired results. Sonic provided a 60”L Coating Control Air Knife with Quick Disconnect Ferrell ends. These Quick Disconnects were suggested along with a spare knife, so that cleaning could be done easily, and a spare for quick change out, allowing the cleaning to be done later while not interrupting the flow of production. The small footprint of the Sonic Blower was also an advantage with the limited amount of floor space available. Sonic also suggested the use of ABS tubing as opposed to Stainless in order to keep the costs down. Sonic was able to address all of their concerns regarding the final coating appearance, reduced maintenance, cleaning issues, while providing cost savings. Sonic also made several visits after the installation to be sure that the customer was satisfied with the performance. Solutions + Support = Satisfaction

Published by: Sonic Air Systems, Inc. 1050 Beacon St, Brea, CA 92821 (714)255-0124 © 2005 Printed in US. Email asksonic@sonicairsystems.com