Graco Inc.

Innovations in Plural Component Proportioning Reduces Waste for CG Power Systems

As technology continues to advance, Plural Component equipment is becoming a valuable way that factories can save money by conserving resources. Because plural component proportioners mix materials directly prior to application and require very little solvent, they significantly reduce build up of wasted materials. This means that expensive materials and solvents can be used for their intended purpose rather than incinerated. Another big advantage of Plural Components is the easy clean up, which simply includes flushing out the system and shutting it down. In response to these positive offerings, finishing companies have become increasingly aware of plural component proportioners and are looking for the optimal system to fit their needs.


CG Power Systems, a worldwide supplier of high quality industrial and consumer products, was in the market to upgrade their older, traditional Graco ProMix system. With the 2K, CG Power Systems was experiencing high levels of waste. Mike Wunderle, Environmental Health and Safety Coordinator for CG Power Systems, reported, “We would generate and pay for the incineration of between four and five 55 gallon drums each month.” This large amount of waste was not only costing a considerable amount of money, but it was also pushing the company’s Small Quantity Generator Status into jeopardy. CG Power Systems was hoping to solve these problems by replacing the 2K with a more advanced system that would hopefully provide savings on waste, decrease VOC’s, and decrease flush times. 


CG Power Systems worked closely with Fluid Air Products in St. Louis, Missouri to come up with the best solution. They decided to replace the old ProMix 2K with the new ProMix PD2K Proportioning System, which allowed them to reduce solvent and material waste by about 80%. The ProMix PD2K is designed to reduce waste by moving the mixing point closer to the gun. This design feature ensures that the material is mixed precisely before it is sprayed. For companies like CG Power Systems, this means lower disposal costs of VOC’s and less wasted paint. This is especially true when working with multiple color changes per day and short pot life materials. Another feature of the ProMix PD2K  are the dosing pumps, which will stall under pressure and use 100% positive displacement technology to ensure accurate mix ratios and consistent performance.


The first aspect that CG Powers Systems noticed about the new PD2K was the quick flush times, which the painters enjoyed. As time went on, Wunderle kept detailed records of paint usage and noted that “the new controller and its activity download make reporting much simpler, significantly reducing my time spent interpreting the output and creating required reports.” Results indicated that since installing the PD2K in June 2015, CG Powers decreased their waste from four to five 55 gallon drums per month to only one 55 gallon drum every five weeks, which is over 80% less waste. Wunderle is pleased with these improvements and expects further waste reduction as the painters continue to master the system and its benefits. 

In addition, the company’s Small Quantity Generator Status has made a dramatic turnaround. Wunderle says, “We have reduced our paint and solvent use to a point where I am able to apply for conditionally exempt status for Hazardous Waste Reporting.” The other benefits noticed by CG Power Systems are that the PD2K is easy to learn, the color changer and cleanout process is simpler and quicker, and that Graco’s product training is supportive and reliable. Overall, the ProMix PD2K allowed CG Power Systems to operate smoothly and effectively while generating less waste and saving money.