Frequently Asked Questions
Answers to Common Questions About Point-of-Application Temperature & Viscosity Control
If you don’t see your question here, let us know.
We use in-line heaters. How is Saint Clair Systems (SCS) temperature control different?
SCS carefully selects the appropriate heat exchanger for each application from a host of options – many of which are patented designs – to ensure that the temperature differentials in the system are safe for the materials being controlled and that the temperature control system will provide long-term, trouble-free service.
This is dramatically different from most in-line heaters, which provide insufficient thermal transfer area to move sufficient energy into the subject fluid without excessive element temperatures. This results in fluid breakdown or premature curing, which then leads to material
defects or internal surface buildup. The buildup is progressive; each layer reduces the thermal transfer rate to the fluid, requiring even higher element temperatures.
Ultimately, most in-line heaters complete the vicious cycle by fouling the heater with contamination defects (dirt) as particles dislodge from the heater wall and make their way into the dispensed fluid.
With SCS temperature control, you don’t have to worry about any of that.
Will the addition of temperature control increase my color change or cleaning time?
No. A properly designed and implemented temperature-control system adds virtually no time or solvent to existing cleaning processes, and we believe that’s essential to optimizing line utilization while minimizing the process waste stream.
I use solvent to control viscosity. How can temperature control help me?
Temperature control keeps solvent cost down. Because temperature impacts viscosity, properly applied temperature control can stabilize industrial coating material viscosity and reduce the amount of solvent used in the process.
Temperature control also significantly reduces solvent-related curing defects such as orange peel, poor adhesion, solvent pop, and gloss issues. That means higher first-pass yield, reduced rework, and major energy savings - not to mention a reduction in harmful air pollutants and reduced exposure to hazardous chemicals.
Is temperature control different from heating?
Yes. In most production fluid-dispensing processes, essential system components add energy to the fluid, which results in excessive heating. Variations in ambient temperature can also change the way that a fluid-dispensing system performs.
Though there are applications where heat-only or cool-only systems are appropriate, in most cases, you get optimal results when a carefully-designed heat/cool system is employed.
How much volume does temperature control add to a system?
A properly designed and implemented temperature-control system will add very little volume to the fluid delivery system – often just ounces. In most cases, the majority of this additional fluid can be reclaimed at product changeover, resulting in minimal waste.
Why does temperature affect my coating process?
All liquids change viscosity as a function of temperature. This relationship is both inversely proportional and non-linear. As the temperature of a liquid increases, the viscosity decreases. Likewise, as the temperature of a liquid decreases, the viscosity increases. Coating materials are no exception.
As a coating material changes fluid viscosity, its behavior in a dispensing system will change accordingly. This is generally compensated for by adding solvent to the coating material (to reduce viscosity) or by changing system pressures.
I use waterborne coatings. Do I need temperature control?
Absolutely. Though most people think of water as being of constant viscosity, the fact is that its viscosity changes by a factor of 2:1 from 50°F to 100°F. This means that any coating made with a water base will change by at least 2:1 over the same temperature range. Since most water-based coating materials also include other solvents in the formulation, the viscosity change is even greater.
I control the temperature of my coating booth. Why do I need temperature control?
Though ambient temperature has a significant impact on coating-material temperature, other factors internal to the application system such as pump pressure, friction, and shear often combine to add more energy to the coating material being dispensed than does ambient.
The effect of ambient is determined by multiple factors, including (but certainly not limited to) the surface area exposed to ambient and whether or not those surfaces are insulated. All of our studies have shown that ambient temperature control alone will not keep coating-material temperature within an acceptable range.
Will temperature control have an impact on my energy usage?
In most cases, yes!
Take a paint application, for instance. When less solvent is used in the paint, less solvent is evaporated into the oven during the curing process. That means that the solvent levels are also reduced, requiring less make-up air to be drawn into the oven and less energy to draw and heat it.
(Note: in situations where the RTO cannot be rebalanced for the lower solvent levels being sent to it, it may be necessary to use some of the saved natural gas to keep the RTO running efficiently. This still results in net energy savings, and since natural gas is significantly less expensive to burn than solvent, there are also major cost savings!)
Will temperature control improve my environmental compliance?
In most cases, yes.
Take a paint application, for instance. When less solvent is used in the paint, less solvent is evaporated into the oven during the curing process. That means that the solvent levels are also reduced, requiring less make-up air to be drawn into the oven and less energy to draw and heat it.
(Note: in situations where the RTO cannot be rebalanced for the lower solvent levels being sent to it, it may be necessary to use some of the saved natural gas to keep the RTO running efficiently. This still results in net energy savings, and since natural gas is significantly less expensive to burn than solvent, there are also major cost savings.)
I’m a spray painter. What defects can temperature control address?
Temperature control can reduce or eliminate several spray and curing defects.
In a fixed-orifice process, such as painting with a paint spray gun, atomization and fan pattern are a function of the combination of flow rate, pressure, and fluid viscosity. A pump's output (pressure and flow) is also a function of fluid viscosity. Therefore, stabilizing fluid viscosity also stabilizes atomization and fan pattern.
This stabilization and control can reduce or eliminate run and sag and dry spray. Better yet, the resulting reduced-solvent coating dramatically decreases solvent-related curing defects like orange peel, adhesion, solvent pop, and gloss issues.
I’m a coil coater. What defects can temperature control address?
Temperature control can reduce or eliminate curing variations and defects.
Coil coating is a special case because variations in fluid viscosity across the width of the strip can cause inconsistencies in film build from edge to edge. These variations in film thickness cause different cure rates across the face of the strip, which intensifies curing-related defects.
SCS’ proprietary Profile Analysis and Correction (PAAC) process specifically addresses this problem. When the variation in temperature (and therefore viscosity) across the width of the strip is eliminated, a smoother, more even coating is achieved, which creates a more even curing pattern.
The ability to optimize coating systems around a stable viscosity allows for significant solvent reduction (and, in some cases, elimination of solvent use altogether), which reduces curing defects such as orange peel, adhesion, solvent pop, and gloss issues.
I work in composite manufacturing. How can temperature control help me?
Accurate temperature control can provide optimal resin performance and reduced processing costs while minimizing styrene emissions.
Gel coat, for instance, must be applied in a smooth, even deposition with no voids, runs, or sags to achieve acceptable aesthetic and performance results. Stabilizing the viscosity of the resin supports this objective and can significantly reduce post-mold rework.
Chop application can be optimized by stabilizing the resin viscosity at a point that minimizes resin usage while maximizing wet-out. In each of these processes, the temperature of the resin affects both curing profiles and styrene emissions (a particularly hot regulatory topic these days). Though heating is often employed alone in these processes, it doesn’t achieve the often sub-ambient set-points required for this delicate balance.
We dispense adhesives and sealants. What defects can temperature control address?
Temperature control can stabilize registration and bead profile.
Sealants and adhesives fall into the class of high-viscosity fluids. While they may share some functions with their coating brethren (e.g. corrosion prevention), they have a much different primary purpose: joining and sealing. Still, they have the same properties as all fluids with respect to temperature and viscosity.
Proper location and thickness, often referred to as registration and bead profile, are the properties necessary for these fluids to perform their primary objective. If the fluid temperature is too high, the viscosity will be too low, which will result in the bead profile spreading out and thinning. On vertical surfaces, it may also "slump", losing its registration. But if the temperature is too low, the viscosity will be too high, which can cause bead profiles to be too high and narrow, and thus unable to cover the area they’re meant to join or protect. Each of these situations can be avoided by accurately controlling the fluid temperature.
Can temperature control be used with 2-part epoxies?
Yes, it can.
Most 2-part epoxies result in an exothermic (heat-generating) reaction when mixed. As this heat builds, the reaction rate increases, which in turn increases the rate of heat generation. This cycle continues until both reactive components in the mix are consumed.
If 2-part epoxy is being applied to a delicate substrate, heating can damage the part. And if the processing rate is not maintained, the epoxy can cure prematurely, resulting in product defect. Since the heating also initially reduces the viscosity (prior to set up), sloughing and improper bead profiles can result.
By adding temperature control, the cure rate and application viscosity can be carefully regulated, and most or all of these issues can be eliminated.
How can temperature control aid my precision machining operation?
Accurate temperature control of the cutting fluid, often implemented on a carefully designed cool-only platform, is essential in controlling costs and ensuring optimal first-pass yield.
Precision machining operations (drilling, boring, honing, grinding, etc.) by nature generate large amounts of heat. High heat is usually mitigated through cutting fluid, which provides both lubrication and cooling. The goal is to reduce the temperature of both the tool and the part being machined to reduce wear and simultaneously increase machining accuracy through controlling thermal expansion.
Why should I work with Saint Clair Systems?
We approach each application with a simple mindset. Either our solutions are a good fit for your process or they aren’t. We have over 30 years of experience and a variety of tools to help us work with you to make that determination quickly. Our reputation is important to us and we will only continue pursuing a solution if we can guarantee that our solution will meet your expectations. Our process for making this determination is collaborative, educational, simple, and sometimes even fun.
What is viscosity, and how can managing it improve my protective coating or sealant dispensing process?
Viscosity is a measure of a fluid’s resistance to flow, and managing that viscosity is critical to improving any dispensing process. In protective coating and sealant applications, viscosity is an important factor in ensuring the coating or sealant is applied evenly and correctly.
How does viscosity control lower operational costs for automated dispensing systems?
Reduced waste: By ensuring that the coating or sealant has the correct viscosity, you can reduce material waste from improper flow or uneven application. This can help to lower the overall cost of process material.
Increased efficiency: When viscosity is properly managed, the dispensing process can be more efficient, with less downtime for cleaning clogged dispensing tips or fixing other flow-related issues. This can increase productivity and reduce the overall cost of labor.
Longer equipment lifespan: When viscosity is properly managed, the dispensing equipment can last longer (it’s less vulnerable to wear from clogging or uneven flow). This can lower the overall cost of maintenance and repairs.
Reduced energy consumption: Proper viscosity management can also lead to reduced energy consumption because the dispensing equipment doesn’t have to work as hard to pump the fluid through the system. This can help lower the overall cost of energy used in the dispensing process.
How will I know if my applications would benefit from Saint Clair Systems technology?
If you are dispensing any fluid, coating, or adhesive in your process, you can benefit from our technology. Take advantage of our free tools to evaluate your process. They’re convenient, easy to use, and will help you understand how much your process can improve with proper temperature and viscosity control. Our experts have over 30 years of experience and are available to discuss your process with you. Feel free to give us a call.
How can I achieve better consistency with my professional automotive spray paint guns?
It’s important that the paint is at the correct viscosity as it leaves the gun, which also means it needs to be at the correct temperature (according to the manufacturer). Once you have the correct temperature and viscosity, make sure that the flow rate and fluid pressure remain constant for repeatability. Use the appropriate tip to give you the correct fan pattern and even coverage. Clean your gun by following the manufacturer's guidelines for regular maintenance.
How does temperature control impact an industrial paint sprayer?
When you control temperature, you are also controlling viscosity. Consistent viscosity leads to repeatable spray patterns and proper coverage and atomization. You will also avoid downtime by avoiding clogged tips and contaminated air caps.
How can I bring viscosity and temperature control issues up to management?
If you notice that you have specific defects, we suggest you track them and see when they occur most. (If you notice runs and sags in the morning because the paint is colder and a little thicker, document the impact that has on the process and your responsibilities. If you have less coverage in the afternoons or experience dry spray, maybe your paint is too hot and solvent is evaporating too quickly. Document that, too.) Management is almost always willing to solve an issue that can be pinpointed and quantified.
Can Saint Clair Systems help my operation diagnose a recurring issue?
When you are too close to an issue or have been doing it for so long, it can become difficult to see what’s right in front of you. Saint Clair Systems has over three decades of experience bringing solutions to a wide variety of fluid dispensing systems and has likely seen the problem you are experiencing. We will know how to solve it.
If my manufacturing process is unusual or unique, can Saint Clair Systems still help?
The principles behind our technology are simple, which means they can be applied to almost any process. The challenge we face most of the time is whether someone is willing to accept a new solution and change the way they’ve always done something. To account for this hesitancy, we have provided a suite of tools to evaluate your process. They’re convenient and easy to use. Take a look to see how temperature change may be impacting your process (and costing you money). If you’re experiencing this problem, we can help.
How can viscosity control improve protective coating and sealant applications?
Coatings and sealants are important in modern products (the waterproofing of phones and watches is just one good example). They require high application consistency and repeatability in assembly. One of the key variables that must be controlled is the viscosity of the fluid. It determines how fluid flows during deposition, after deposition, and how the final “seal” ultimately performs.
If my manufacturing process is unusual or unique, can Saint Clair Systems still help?
The principles behind our technology are simple, which means they can be applied to almost any process. The challenge we face most of the time is whether someone is willing to accept a new solution and change the way they’ve always done something. To account for this hesitancy, we have provided a suite of tools to evaluate your process. They’re convenient and easy to use. Take a look to see how temperature change may be impacting your process (and costing you money). If you’re experiencing this problem, we can help.
How can viscosity control lower costs for industrial finishing systems?
One of the most significant costs in industrial finishing is associated with rework and scrap. Rework, in particular, is implemented to increase the first pass yield (FPY) of the process. Rework operations frequently target defects like gloss and orange peel, which result from variations in fluid viscosity during application. By carefully controlling coating viscosity, FPY can be increased, thereby reducing the overall cost of the operation. To find out how much temperature change may be costing you, try our free waste calculator.
How can consistency be achieved with professional automotive spray paint guns?
The key to high-quality finishes, such as those in the automotive industry, depends on the viscosity of the paint being applied. Viscosity directly affects the size of the droplets in the atomized cloud and how the electrostatics affect those droplets. Viscosity also determines how the droplets behave during the application process.
For instance, if the viscosity is too low and resulting droplets are too small, they may get caught in the booth air draft and drawn away from the part. Or they may lose too much solvent between the time they are atomized and the time they hit the part, resulting in a dry spray condition. On the other hand, if the viscosity is too high, and resulting droplets are too large, they may create too heavy a film build, resulting in orange peel and/or run and sag.