Graco Inc.

From pneumatic to electric to save energy and increase overall quality

Fiat Chrysler Automobiles (FCA) designs, engineers, manufactures and sells passenger cars, light commercial vehicles, components and production systems worldwide. The Group’s automotive brands are Abarth, Alfa Romeo, Chrysler, Dodge, Fiat, Fiat Professional, Jeep, Lancia, Ram and Maserati. They are present in 40 countries worldwide. As the seventh-largest carmaker in the world, FCA carries on the traditions of two historic car manufacturers: Fiat, founded in 1899, and Chrysler, founded in 1925. FCA is constantly striving for innovation and green solutions.

Saving energy while improving quality

In the FCA’s Mirafiori plant (Italy), the production line of Maserati Levante models was equipped with Graco Monark 23:1 pumps to dispense a medium viscosity sealant to a single operator in order to apply it manually on specific parts of the car’s body. Every Monark pump was fitted with an external air and fluid filter, a surge suppressor and an air-operated fluid pressure regulator to achieve the right amount of sealant depending on the specific requirements linked to the car body parts to be sealed.

FCA was looking for an innovative product to renew the installation of air-operated piston pumps with an innovative product. The requirements included saving energy, keeping the working area silent and increasing the overall application quality. Local distributor Deri proposed a solution to optimise the application with the e-Xtreme, an electrical airless pump recently launched by Graco. The test took place over four months, using one e-Xtreme connected to three manual applicators, running around the clock.

From now on, FCA has chosen the e-Xtreme as its standard solution for this application. All Monark pumps will be replaced by e-Xtreme pumps in all FCA plants.

Fewer pumps, more efficiency

The right configuration has been selected based on the technical requirements. Not all pumps need air, as long as they receive low electrical energy (220 volts, 16 amps). The surge suppressor has been excluded, as the e-Xtreme has an imperceptible pulsation at the gun due to an innovative, intrinsic pulse reduction at the engine. A new fluid pressure regulator (not air-driven) was selected to allow operators to maintain their fine-tuning capabilities.

Most importantly, the e-Xtreme could be connected to up to three guns at the same time, as the right minimum flow rate and pressure was needed. This limits the amount of pumps that have to be installed. Moreover, the pump shows a limited difference between static and dynamic pressure, virtually eliminating the amount of variation in dispensing sealant when opening or closing the gun. In addition, a further asset is that compressed air is no longer necessary for this application.


The e-Xtreme has some innovative solutions which have been carefully evaluated by FCA’s technical engineers:

  • No pulsations
  • Noise reduction, improving working conditions
  • Fully electrical solution which assists energy optimisation and efficiency
  • Atex approved (ATEX, IECEx, and Class 1, Div. 1 approvals)
  • Easy to operate and adjust
  • Integrated fluid filter at the lower for saving space
  • Reduced difference between static and dynamic pressure
  • No ice production
  • Extended warranty on electrical components
  • Compact and innovative design
  • Equipped with a lower of unbeatable and proven longevity