【Burden of Replacing Activated Carbon Filters】Criteria for Considering Equipment Renewal on Painting Lines Operating for Long Hours

On painting lines that operate for long hours, every filter replacement requires labor and working time, and in some cases, the equipment must also be stopped. The burden on the worksite is not determined only by the number of replacements. It also changes significantly depending on the time and number of people required for each replacement and the duration of the equipment shutdown.

Therefore, when considering equipment renewal, it is necessary to identify what is creating a burden under the current operation and to consider reviewing not only the performance of the filter but also the replacement method itself.

This article explains why filter replacement becomes a burden on painting lines operating for long hours, the points to check before equipment renewal, and the option of an automatic switching system.

Table of Contents

• Why Filter Replacement Becomes a Burden on Painting Lines Operating for Long Hours
• Operating Conditions to Check Before Equipment Renewal
• What Types of Worksites Are Suitable for an Automatic Switching System
• TS5000S as an Option for Long-Hour Operation
• FAQ

■ Why Filter Replacement Becomes a Burden on Painting Lines Operating for Long Hours

At worksites where painting lines are operated continuously for long hours, filter replacement also becomes one of the ongoing maintenance tasks.

If the replacement frequency is high, the number of replacement tasks increases accordingly. On the other hand, even if the replacement frequency is not particularly high, the impact on production may become significant when each replacement requires a large amount of labor or time, or when the equipment must be stopped.

Therefore, when considering equipment renewal, it is necessary to look not only at the performance of the filter itself but also at how much labor and shutdown time are required for the replacement work.

■ Operating Conditions to Check Before Equipment Renewal

The first point to check is which filter is actually creating the burden.

The role and operating conditions of a filter differ depending on its installation location, such as the painting booth, the air supply side, or the exhaust side. When considering equipment

renewal, mainly organize the following items.
・Filter installation location
・Current size
・Replacement frequency and replacement criteria
・Time and number of people required for each replacement
・Whether equipment shutdown is required and the duration of the shutdown
・Line operating hours
・Space available for installing new equipment

By organizing this information, it becomes easier to determine whether replacing the existing filter will be sufficient or whether the replacement method itself needs to be reviewed.

■ What Types of Worksites Are Suitable for an Automatic Switching System

One way to reduce the burden of filter replacement is a system that automatically switches from the filter currently in use to a new filter.
In particular, it is worth considering at worksites that operate for long hours or continuously and require labor or equipment shutdown every time the filter is replaced.
On the other hand, if the replacement frequency is low and the work can be completed easily in a short time, continuing the current operation may be more reasonable.
When renewing equipment, it is important to compare not only the filter price but also the labor required for replacement work, the shutdown time, and the impact on production.

■ TS5000S as an Option for Long-Hour Operation

TS5000S is a carbon roll filter for long-hour operation provided by TS COATING. It uses a mechanism that automatically switches to a new filter when the adsorption capacity is exceeded. Its size is 1,850 mm × 20 m × 1 mm, and the material is polyolefin.

For installation, check the current filter location and replacement frequency, the conditions of the air to be treated, the method of connection to the existing equipment, and the installation space.

Please contact us individually regarding whether it can be applied to your equipment and under what conditions it should be considered.

※For more details, please download the materials or contact us using the form below.

■ FAQ

Q1: Is there any reason to consider equipment renewal even if the replacement frequency is not high?
A1: Yes. This is because the burden on the worksite may become significant depending not only on the number of replacements but also on the time and number of people required for each replacement and whether the equipment must be stopped.

Q2: What types of worksites are suitable for an automatic switching system?
A2: It is suitable for worksites that operate for long hours or continuously and require labor or equipment shutdown every time the filter is replaced.

Q3: What should be checked before installing TS5000S?
A3: Check the current filter location and size, replacement frequency, the conditions of the air to be treated, the method of connection to the existing equipment, and the installation space.

※For more details, please download the materials or contact us using the form below.