Some Typical Plants.

An interesting Airostyle plant is shown in Figs. 95, 96 and 101, and is arranged for 16 operators to deal mainly with bronze lacquers, hence the somewhat simple arrangement with no provision for adjustment of pressures at each hood.

It will be noted that the ventilator employed is of important size; the compressor delivering air to the plant is stationed in the basement.

The views of the plant are excellent, and serve to remove the erroneous impression that such a plant cannot be conveniently and economically arranged, both as regards floor space occupied and the provision of adequate gangways on all sides.

Another interesting Airostyle plant is shown in Figs. 84, 85 and 86, and was installed for japanning gas fires, radiators, gas cookers, etc. An item worthy of note in this plant is the patented hot air apparatus installed for warming the japan and for also heating the sprayer and flexible tube conveying the japan to the sprayer; it is clearly seen in the centre of the two hoods. The large hood is mainly used for radiators, which are wheeled on to the large ball-bearing turn-table, shown white for the purpose of a clearer view, but when not so used a table is wheeled into position and two operators are accommodated for smaller work.

The power unit, consisting of electric drive and suitable overhead countershaft, together with the compressor and ball-bearing fan, is shown in Fig. 100, and is directly outside the japanning shop.

This plant was installed for the Davis Gas Stove Company, Luton, and has been in operation for several years.

The compressor shown in Fig 98 also delivers air to the gas cooker department for two or three operators, and to the porcelain enamelling department for six or seven operators, but as the same practice is adopted as is shown in the photos here reproduced, no useful purpose will be served in describing them in detail.

Undoubtedly one of the most important plants in the country, and one producing the highest finish, is installed at Messrs. Joseph Lucas, Ltd., Birmingham, and the photographs reproduced here are by their kind permission. The author was granted the privilege of inspecting the plant fully, and proposes to enlarge upon its arrangement and capacities for saving of labour, etc.

The whole of the work was carried out by Messrs. The Airostyle and Lithos, Ltd., and it must be admitted that the plants are so arranged as to admit of rapid handling of the work, and the subsequent stoving of the articles is just as conveniently provided for.

Two distinct plants are in use at the moment with a separate steel plate central draught fan and a water-cooled air compressor (the type of fan and air compressor employed is shown elsewhere in the book, see Figs. 71 and 79).

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On referring to the drawings Figs. 97, 98 and 99, showing respectively an elevation, end view and plan of one of the plants, it will be seen that the plant is divided up into two bays, each accommodating six operators, so that, in all, twenty-four operators are provided for in the two plants and were actually seen at work.

It will at once be noticed that ample space between the bays is provided, and this is most essential in order to give sufficient room for the racks which are wheeled into place behind each operator. These racks are readily seen in the photographs, Figs. 103 and 106, and can also be distinguished in Fig. 104.

The japanning shop in which the plants are installed is of large dimensions, 250 feet long by 48 feet wide, and is extremely light and airy, but, owing to the fact that the roof-lights are now painted over (by Government regulations), the shop at present appears to disadvantage, and the photographs consequently suffer.

The photographs, nevertheless, show very clearly what an immense amount of work can be daily handled, but, notwithstanding this, the writer was assured that there were still numbers of brush hands in the shop. This was primarily due to the fact that full arrangements for spraying are not yet completed (12 more operators are being provided for), and, secondly, to the fact that certain work needing a large amount of masking can be almost as readily brushed, and this class of work finds employment for brush hands. Messrs. Lucas, Ltd., admit that there is a wastage of japan, but maintain that a heavier and much more even coat is applied with a superior finish to brush work, and that there is an enormous gain in time of about 4 to 1 over brushing.

They state, also, that an indirect gain is obtained in the economical working of the stoves, for these are filled far more quickly, and, consequently, the daily output per stove is correspondingly increased.

A striking proof of the saving is their statement that if they had not the system of spraying at work, it would have meant 200 hands in the japanning department, whereas they now employed only 90, and a considerable number of these were engaged upon brush work, so that if only the whole of the work could have been handled with the spray, then the number of hands necessary would have been even less than 90.

The photographs, Figs. 105 to 107, need no description, and are self-explanatory to a large extent.

The type of instrument used, and the accessories, are described in detail elsewhere, as they are the standard practice adopted with all Airostyle plants.

The writer also had the privilege of inspecting another interesting Airostyle plant, installed at Messrs. G. Cabdy and Sons, Birmingham, where 7 or 8 operators are employed upon high-class celluloid enamel finishes upon buttons, medallions, cameos, electrical fittings, and last, but not least, numerous parts for munition work, such as cartridge clips for 18 or 24-pounders, etc.

The small articles are laid on a grid measuring about 11 inches by 9 inches, and while holding the grid the operator sprays over the whole of the article on the grid, and in the case of rounded faces of buttons, sprays these obliquely from all sides in turn, as well as over the tops of the buttons.

It may be mentioned that the greater part of the spraying paints and enamels are supplied by Messrs. Thornley & Knight, Ltd., of Birmingham.

The Birmingham Small Arms Co.

The cycle department of this well-known firm deals with an enormous, amount of parts, and a new paint spraying department on an extensive scale is in course of construction at Redditch, and the method in use at the Birmingham works will be to a great extent followed. In both cases the "Midland" sprayer is used under a pressure of from 30 to 50 lbs.

The method is very thorough, and although comparitively expensive is well calculated to produce a finish which is (a) capable of withstanding hard wear and possible knocks and (b) absolutely rust-proof. The finish is elastic and very durable. It is produced by the following method. The steel or iron parts are first thoroughly washed in pure American turpentine in order to remove every trace of grease and dirt. In passing, it may be said that a suitable white spirit would probably answer as well and would effect a considerable saving, although it is possible that the pure turpentine leaves a certain residue behind it which is of advantage in forming a key to the subsequent coats. The parts are then stoved, when a coat of pure Baltic linseed oil is applied by means of brushes, and they are again stoved at 250° F. Then a coat of black japan, known in the works as "rubber solution," is sprayed on, and a third stoving is given in this case at 280° F. This is followed by two coats of khaki-coloured enamel sprayed on, which dries with a semi-gloss finish. The parts are stoved between each coat and after the final coat, so that they receive five stovings altogether.

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The ovens are of special construction and are described in detail elsewhere. The japans employed are supplied by Messrs. Arthur Holden and Co., Ltd., of Birmingham.

Samples of the work thus finished were submitted to the author, who carefully tested them. He found that the finish was all that could be desired. A piece of plate metal, for instance, was bent double without the finish being affected, thus showing very clearly the great elasticity of the coating—a most important and necessary quality in a finish for this class of work.

Messrs. Fletcher, Russell & Co., Ltd.

This well-known firm use spraying at their Warrington Works on an extensive scale. All parts of gas cookers, gas stoves, and ranges large and small, are sprayed by different sizes of the Airostyle sprayer. Stoving takes place in most cases, and the work of spraying effects a great saving, one man being able to do the work of at least three under the old brush system.

Some very beautiful effects are obtained in stoves intended for use in drawing, dining and reception rooms, by spraying various coloured semi-transparent lacquers over silver-bright iron or steel. Rich reds, browns, greens and blues in various shades are produced, and the bright surface beneath the lacquer gives a very pleasing and artistic effect. Stoving produces the necessary hardness of the lacquer, which may be regarded as being very durable.

Special Machines.

The Berkel and Parnall's Slicing Machine Co., Ltd., whose extensive works are at 6, Bow Common Lane, London, E., have had a plant for paint spraying in use for the last four years, and find it to be quite successful and a great saving of time over the old method of applying the paint by means of brushes, in addition to a superior finish being obtained. The sprayer in this case is the "Invincible," and the paint is sprayed on under pressure varying according to the nature of the work. The iron parts which go to make up the slicing machine are first primed and stoved and any imperfections stopped in the usual manner. They are then painted by means of compressed air and again stoved, after which they receive a further coat, which is also stoved. Various ornamentation in gold is then put on, mostly by the transfer process, although certain parts require lining by hand. The final coat of varnish is given by means of brushes, it being found that this is the most economical way for this particular class of work. In this particular it will be observed that the method differs from that used in many other works where all the operations are done by spraying, including a final coat of varnish. The colour used for the paint is a bright red. There are two spraying cabinets with the usual exhaust, and turn-tables are employed for turning the parts round to receive the coat of paint. It may surprise some readers to learn the very large extent to which these slicing machines are used throughout the world for various purposes.

Gittings, Hills and Boothby, Limited.

The plant for spraying in use in these works is principally intended for experimental purposes in connection with the preparation of paints, varnishes and lacquers of various descriptions which the firm manufacture. An up-to-date type of pistol is used, with a pressure not exceeding 30 lbs. to the inch. The work is done in a small closet with glass sides open at one side, and a small turn-table is employed upon which to place the article that is being sprayed. Some admirable results are obtained with the aid of gold lacquers. It is found that in certain varnishes the application of heat is an advantage, but as a rule the spraying is done cold. Among the articles which have been painted are motor cars and various smaller appliances.

The Kingsbury Manufacturing Co., Ltd.

A typical plant for finishing picture frames, furniture, fancy articles such as wood, cane and other ornamental baskets, is that of the Kingsbury Manufacturing Co., Ltd., 1, Markfield Rd., Broad Lane, Tottenham, N. This firm are the inventors of what is known as the "Inolite" system of gilding, which is described as an ideal process. Certainly the work produced is as near perfection as one would desire, the gilding being excellent in appearance, while it is guaranteed for five years to be free from discoloration or tarnishing. The process consists in applying by means of spraying, first, a coat of special enamel, which when dry is rubbed down with a solvent applied by a pad. Upon this is sprayed a coat of gold paint, and a final coat of colourless celluloid varnish is given which protects the gold from tarnishing. The process adopted is described in greater detail under the head of "Picture Frame Finishing" in this book.

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The coloured celluloid enamels which are applied to fancy baskets, etc., have a very attractive metallic appearance, which is far superior to the ordinary crude bronzy effect. Another speciality of the firm is the finish of frames in special black, which gives a perfectly smooth finish which might be called "egg-shell gloss." It is quite artistic in appearance, eminently suitable for the particular purpose, and gives a durable frame at a comparatively small cost.

The firm estimate the saving of time by using the spraying as compared with that of employing a brush is as 5 is to 1. They point out that a little extra material is required, but this is not begrudged as it possesses advantages in an increased durability of the protective coating.

The Gas Light and Coke Co.

Several of the works of this company, which deal with gas meters, are fitted with paint spraying installations. The branch at Laburnum Street, Kingsland Road, in charge of Mr. W. F. Fagan, may be taken as a type. Two Aerographs and three Airostyles are in use. The old meters that come to the works are examined, and if the paint is in fairly good condition the surface is rubbed down with pumice stone and water, but if it is much decayed the meters are placed in a hot bath containing a solution of lime and caustic soda, and allowed to remain in it a short time, when the paint becomes so soft as to be easily removable. The surface of new tinplate is cleaned down with spirit, when it is quite ready to receive the coat of paint. At these works many different makes of meters come in to be dealt with, hence various masks are necessary to protect those parts which it is not desired to spray. The pressure used here is rather more than usual, being 40 lbs. to the sq. inch. The time taken to paint a meter is very small, as can be understood when it is said that two men working on five-light meters can turn out 30 an hour. Before the spraying apparatus was put in, about a year ago, a man could paint with a brush about three meters in an hour, so that, with the present system, there is an immense saving. It is calculated that the whole of the original outlay of putting in the plant will be returned at the end of about a year.

The masks or shields having been placed in position, a cap is placed over each union and the paint is sprayed on. The meters are turned out at the rate of 900 to 1,500 a week of 48 hours. The spraying apparatus is provided with the usual exhaust consisting of two 9-inch holes to each cabinet, with grating over. About 10 per cent, more paint is allowed than that used when it is applied by hand, but the greater part of this goes on the surface, and the coat of paint as a protector is distinctly improved. The exhaust is carried up to the roof, but the actual loss of paint is very small.

Fig. 108 shows a general view, and a large central draught steel plate fan is employed to exhaust the hoods, and to drive this and the compressor a gas engine is employed. The compressor is of the type illustrated in Fig. 71, page 115, and can just be discerned behind the gas engine.

Fig. 109 shows a gas meter in position, with the necessary masks fixed, and Fig. 110 shows the operator about to spray-paint same. This plant has been in daily operation for more than two years.

The Gas Meter Co., Limited.

The installation of a spraying plant at the works of this firm, which are at 238, Kingsland Road, have been in operation for rather less than a year, but has proved quite satisfactory. Various types of gas meters are sprayed with one coat of Torbay paint, which is an iron oxide paint of high quality, and the one coat possesses amply sufficient quality to give a good covering. Prior to painting the surface of the tinned plate which is used for gas meters, it is cleaned down with a piece of waste dipped in spirit. Masks are used to fit over name plates, etc., and the spraying is done in the usual cabinet, with an exhaust. A three or four-light meter takes about two minutes to do, and the larger sizes, of course, longer in proportion. All sizes up to and including 500-light meters are sprayed, but those larger, up to 1,000 lights, are a little too big to handle. The greater part of the meters are done in deep red oxide iron colour, but three other colours are used in addition, as may be required. The meter to be sprayed is placed on a turn-table which bears on a sharp steel point and has on its upper portion spikes or ridges, to hold the meter in position. The Aerograph spray is employed in this case.

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