Eighteen Gresham, Oregon painting professionals participated in a special 3D virtual reality (VR) training to improve efficiency and reduce waste in their operations. The skills they learned are estimated to save them close to 30% on the cost of coating materials (paints and clear coats) in their operations, along with providing human health and environmental benefits.
The training was held on March 22, 2024, through a collaboration of a local government agency and two non-profits: the City of Gresham, the Rockwood Community Development Corporation’s East County Business Bridge (ECBB) and the Pacific Northwest Pollution Prevention Resource Center (PPRC). Gresham’s Business Sustainability Coordinator, Gregg Hayward and Gresham Watershed Analyst, Keri Handaly; Rockwood Community Development Corporation’s East County Business Bridge’s (ECBB) Ulu Seria, Ashley Pugh and Gustavo Gutierrez-Gomez; and PPRC trainers Angel Contreras Cruz and Michael Strauhal were all key to the project.
The training was offered in English and Spanish since two thirds of the attendees felt more comfortable taking it in their native language. By offering interpretation for technicians whose primary language is Spanish, PPRC helps to bridge the environmental justice gap for this demographic. Still, small shops have several barriers since waterborne paint and equipment are big investments. However, shop owners and technicians understand the real benefits of the spray efficiency techniques and best management practices offered in PPRC’s well-designed training program. The power of collaboration is demonstrated in this event. Partnerships with other organizations and local governments allowed this training to reach a broader audience. PPRC is committed to continue working with other organizations and local governments to train technicians in the spray-painting industry with the goal of minimizing waste, maximizing profit, reducing environmental harm, preventing pollution, and creating healthier communities.
Participants were recruited via on-site visits by the City of Gresham, phone calls from PPRC and ECBB, emails from PPRC, and social media posts from PPRC and ECBB.
This training includes a lecture and hands-on practice using 3-D Virtual Reality (VR) with Laser Technology equipment. It begins by having the painters use the VR equipment to “spray/paint” a virtual autobody panel as they normally would. The trainer then gives a 60-minute lecture to teach technicians how to improve their techniques and efficiency and minimize overspray. The VR simulation provides spray coaters (painters) with data on how they spray and their techniques, to help them improve their efficiency. They learn to minimize overspray. This lowers costs of materials and reduces waste. Painting more efficiently can also reduce health risks associated with exposure to the coating materials for the painters and the surrounding community.
There are specific modules for different types of painters in the virtual reality simulation; automotive spray painters see autobody door panels, fenders, or hoods, and they coat them virtually. In these pictures, you can see a coater spraying the panel with red paint. The screen shows what the painter sees through the VR headset. The SET equipment also measures the thickness of the paint and the overspray.
Fourteen local autobody painters from nine shops and four house painters were trained. The autobody shops shoot both solvent and water-borne coatings. 100% of the painters in attendance reported that the trainers are a reliable source of information and that the training will help them reduce overspray and be more efficient. Only one of the painters in attendance had ever had the transfer efficiency of their painting measured prior to this training.
Painters pride themselves on quality workmanship and experience. However, if asked, “Where did you learn to paint?” Most painters learn from colleagues who also learn from other colleagues. Therefore, the importance of this training lies in the techniques painters will acquire, including technical elements such as triggering the gun, reducing overspray, and cutting down lead and lag. A lack of proper training can result in paint waste, increased material costs, increased environmental impact, and inefficiency in the painting process. Traditional spray-painting training using shop equipment and spraying actual coatings, while crucial, wastes paint and limits practice opportunities.
Painters used the VR equipment to “paint” the autobody panel before receiving the training. After the instruction, they used the equipment to implement what they had just learned. One of the primary techniques they learned is to trigger the gun at the end of a run. This act alone typically saves about 20% of material that would otherwise be wasted. Each painter took a turn to show their improvement. Typically, it only takes one or two runs after training to see real improvements.
On average, prior to training, painters sprayed $17.68 worth of coatings and wasted $5.07 worth of coatings. That is a 29% waste rate. After the training, the painters sprayed $12.05 worth of coatings to achieve the same result on the painted surface. This is a 32% savings of materials used. Painters also wasted less. Both the amount of coating material used, and the waste rate went down because of this training.
In addition, reducing the amount of paint sprayed can lower the health risks associated with exposure of painters and the surrounding community to hazardous chemicals, including volatile organic compounds (VOC). VOCs are one of the components in ground-level ozone, or smog.
The result is that painters can practice and improve their skills in a risk-free environment. They improve their consistency by laying down an even thickness of paint, resulting in higher quality finishes. They improve their efficiency, resulting in material cost savings, reduced emissions, and reduced exposure to harmful chemicals.
Seven trainees obtained the 6H NESHAP certification, which is required by U.S. EPA for those who paint with coatings containing one of the five primary metal or metal compounds covered by this regulation: lead, nickel, manganese, cadmium, and chromium.
For more information on PPRC’s Spray Efficiency Training, see https://www.pprc.org/spray-efficiency. Contact Ken Grimm or Mikey Strauhal to schedule training.
Check out our Spray Efficiency Training videos below!
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