Vapor Bus International
Buffalo Grove, Illinois
Intern: George Ioannou
University of Illinois, Chicago
Vapor Bus International specializes in the manufacturing of passenger bus
door systems and related accessory systems to the transit bus industry. The
manufacturing facility in Buffalo Grove has over 120,000 square feet of office
space, manufacturing operations and warehouse areas.
The intern focused on strategies for improving transfer efficiency in the
powder coating operation, reducing the costs associated with the metal preparation
process, and reducing the amount of natural gas that is consumed at the facility.
Results:
The current powder painting process is a spray to waste system. Paint that
does not initially adhere to the substrate is collected and then discarded.
The facility is in the process of changing to a powder coating system that
would hold a greater charge and thus increase the first pass transfer efficiency.
A climate controlled booth is being investigated, whereby paint reclaim would
allow the paint to be more effectively utilized until it has been consumed.
In the metal preparation process, the intern investigated ways to extend the
life of the acid etch tank. The intern researched a microfiltration system,
an aerator and the use of a detergent. An alternative to the acid solution
was also researched. It was found that with some modifications, the acid tank
could be changed out three fewer times per year, resulting in $10,000 annual
savings.
The intern determined that the installation of a heat exchanger (economizer)
in the air make-up unit could save the facility approximately $40,000 a year
in natural gas usage.
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