So you’re considering if you need a custom grounding solution for your automated paint/powder coat line, but you still have questions and concerns.  You’ve probably evaluated all your alternatives and realized it may be time to update your grounding process, and maybe you've even read our whitepaper on Static Electricity and Grounding in Industry. But there are still some questions and things to consider.  This infographic addresses the common questions and considerations that people have when evaluating grounding solutions.

 Ready to move ahead with a custom or ready-made solution for grounding to update your process? Click here and fill out the form to get the ball rolling!   

You can also read our free guides to grounding for plastic and metal painting below

When trying to determine the cause of problems encountered with electrostatic painting, it can be confusing. The problem is often solved by updating the grounding process, however this simple solution is often overlooked. 

1. There is a drop in transfer efficiency

Your measurements and output are lower than they should be. 

2. Paint thickness is not what it should be

You may see a reduced paint thickness, uneven paint thickness, or both.  

3. There is a lot of scrap/rework

Lack of a good ground can result in much higher  amounts of scrap and rework than there should be. 

4. There's more paint on the surrounding surface than on the substrate

This can indicate you had a bad ground or no ground at all. 

5. Your cost of paint has gone up

You are going through more paint to coat the same number of items. 

6. Servicing the robots doesn't help

You may have thought there was something wrong with the paint robots, but they are in working order

7. There's a drop in weight

If your substrates come out weighing less than they normally do, this can indicate that less paint is making it to the surface which usually indicates there're something wrong with the ground.

If you think updating your grounding process will help, you can head over to this handy page which addresses the most common considerations and questions for updating your grounding process. 

For more information on grounding, read our whitepaper Static Electricity and Grounding in Industry. 

You can also take a look at our free guides for grounding plastic and metal for painting.

With the vast varieties of paint, materials and application processes, the achievement of an efficient, high-quality and consistent automated painting process can often seem elusive. How can the director of the painting operation optimize output and quality while controlling costs?  Output is useless without quality.  The cost of scrap and rework adds up quickly, and can delay the overall project. For example, if a painted plastic bumper cover has flaws and needs to be reworked or scrapped, then that component will not be available for assembly to the designated automobile, potentially impacting the production line or the customer (and who wants rework stacking up?). This is a disruptive and costly nuisance.

A clean painting environment promoting "high transfer efficiency" is always a good place to start. But that alone does not guarantee a flawless paint finish. A major contributor to poor paint finish quality in plastics is ineffective electrostatic grounding resulting from poorly grounded components.  Yes, something a simple as grounding!  Paint departments use a variety of grounding methods including conductive tape, foil, clip assemblies, and grounding fixtures (of which some are internally integrated).   Each of these grounding methods have varying degrees of effectiveness and cost.  Here are some of the cost factors to consider:

• Inventory: What are the associated costs to purchase individual grounding components and to monitor / maintain inventory levels?
• Labor: What are the associated costs to build assemblies in-house, using your own staff, as opposed to buying a complete assembly?
• Set-up/Clean-up: What are the costs of set-up and clean-up?
• Effectiveness & Ease of Use: Is the grounding method reliable, repeatable, reusable & cleanable?

Many paint shop process foreman are inclined to think that a "do-it-yourself" grounding solution is the best, cost-effective option.  In reality, a solution engineered to your specific set-up will provide a superior, LOWER-cost result.  Don’t do it yourself!  

• Customized to the exact requirements of your process. Each is precisely made and consistent.
• Finished assembly cost is less than the cost to purchase individual components and build them yourself with in-house labor.
• No scrap, broken or missing parts. Fully built assemblies arrive ready to use.
• Less administration cost to order, stock, receive and count not to mention – fewer SKUs.

There are many outlets offering standard grounding assemblies and individual components, but it's the application knowledge and expertise that make it work.  Mueller Electric Company has that proven electrostatic grounding solution expertise and field experience.  Mueller offers applications engineering, a wide range of grounding solutions for any plastics painting production line, and samples for testing.  The right solution is a phone call or email away.   

For more information on grounding, read our whitepaper Static Electricity and Grounding in Industry.