Year Completed: 2011
Coating Used: Mascoat Industrial-DTI
Thickness: 40 mils (1mm)
Reason for Application: Angel hair
"Angel hair" is a very common problem for packaging companies. Angel hair consists of long, slender strands of plastic that clog up the screen on the molding machines, causing constant maintenance issues.
A packaging company in Texas was having this problem in their facility. The temperature of the pipe can affect the amount of angel hair, so the company looked to Mascoat for their insulation solution. Mascoat found that the aluminum pipes on the roof of the facility were getting up to 150°F (66°C) the summer time and estimated that applying 40 mils (1 mm) of Mascoat Industrial-DTI to the 3” (80mm) pipes would reduce the surface temperature by 25–28°C, depending on ambient temperature.
The project was completed in October of 2011, and the company contacted Mascoat in January of 2013 to adopt the same method at their other facilities. When asked about the performance of the coating at the original jobsite, the company’s engineer in charge said, “we saw a 60–70% improvement over the non-insulated piping. Before the application, we were cleaning screens once per shift. In the heat of the summer, the operators now clean the screens once per day (three-shift per day work schedule). The operators are very pleased with the results!”
In addition, he explained how Mascoat’s coating allowed them to implement an innovative idea for the wintertime when they would occasionally run into condensation issues. Water condensing in the storage silos caused wet pellets, which are not useable. They channeled the exhaust from the vacuum pumps (100°F or 38°C) through a heat exchanger to heat the air used for transporting the pellets. Since this air comes from the factory (50% relative humidity) and is heated to 90°F (32°C), this makes for fairly dry/low humidity air. As the damp pellets are transported through the insulated piping, the air picks up the moisture and leaves dry pellets in the factory. Since they implemented the idea, they have not had a single incident of wet pellets.
Not only did the insulation help reduce angel hair in the summer; it also helped them reduce the impact of condensate in the winter. The company plans to use Mascoat on future maintenance projects.