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Home | Editorial Spotlight | Improving Spray Foam Applications
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Improving Spray Foam Applications

A new chemical processing system streamlines SPF projects tenfold.

By Juan Sagarbarria

The spray foam industry is in a state of constant growth, and as such, manufacturers of spray equipment are ferociously developing cutting-edge tools and gadgets to simplify the array of products that constitute the application of foam.  These developments are crucial to the future of the industry, as it is a certainty that anything that facilitates the complicated process of chemical mixing and enhances the yield, output, and application of the foam allows for a greater number of jobs to be completed. Ease of operation also attracts others that are on the fence to start up an SPF business, or for existing contractors to add SPF to their services.

The on-going upgrades of SPF equipment have brought turnkey rigs to the forefront. They are a common sighting at many a jobsite, but even those recent developments are likely to evolve – and they have. In actuality, manufacturers like Akurate Dynamics take upon themselves the responsibility of creating spray foam equipment that fundamentally improves foam applications by solving the spray foam industry’s most pressing on-the-job issues. Their latest innovation – the Delta Chemical Processing System (CPS) – is an auto-calibrating spray foam application system that introduces a whole new ball game of user friendliness, offering a direct response to many of the challenges that spray foam contractors face on a daily basis with displacement systems. What problems are those? Let’s run through them.

REDUCING LIABILITIES VIA QUALITY CONTROL

In the past, spray foam contractors utilizing common displacement systems, that is proportioning machines containing pumps that are double acting and displace A (isocyanate) and B (polyol resin) materials, have had to rely on visual inspection to estimate the quality and the output of the foam. Due to this fact, spray foam chemicals can be sprayed with off-ratio isocyanates or resin-rich foams to large areas of the project. This, in turn, can bring about liabilities derived from an improper application via failure to meet the specifications set by the foam manufacturer, which could result in a lawsuit for the contractor or builder.

Akurate Dynamics designed the Delta CPS with a Human Machine Interface (HMI) computer-controlled system that controls the pump speed and adjusts the chemicals passing through the flow meter at a 1:1 ratio with a two-percent margin of tolerance. By providing this automatic function, the Delta CPS allows the foam to be applied correctly to the chemical manufacturers’ specification, and the job to be properly completed. Furthermore, the Delta CPS has the ability to produce closeout documents that show that the foam was sprayed to the manufacturer’s specifications. This documented proof mitigates liabilities for the builder and contractor and helps them maintain a clean track record for future jobs.

“The Akurate computer-controlled system takes care of on-ratio monitoring accurately and continuously, adjusting the system components automatically to keep the foam on-ratio at all times. With most systems, there is no evidentiary proof that the job was sprayed on ratio,” says Trey Cook, president of Akurate Dynamics. “Our auto-calibrating chemical processing system provides a recorded data log that shows that the SPF was installed on ratio according to the manufacturer’s specifications. With this on-hand documentation, the probability for any liability issues is much, much lower.”

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AKURATELY-MADE Akurate Dynamics’ engineering and manufacturing teams design and produce all spray foam equipment in-house.

LESS DOWNTIME

In spray foam applications ¬– and many other things in life – time is money. Case in point: The average displacement system can take up to 45 minutes to mix and heat the chemicals before it’s ready for foam application. While there are contactors that could argue that this time is utilized to wrap up the prepping of the work area, others would prefer that the mixing time was cut in half to get to work quicker.

To reduce the aforementioned downtime, Akurate Dynamics assembled their Delta CPS with a mixing system that continuously blends the chemicals during the entire job. The automated mixing system yields a thorough mixing of Appendix-X materials by both circulating and blending the chemicals without introducing agitated air pockets. The mixing system allows the chemicals to blend and the contractor to be spray-ready in 15 minutes. That’s half an hour of work gained.

“Once the chemicals blend, contractors don’t need to worry about the labor-consuming task of changing drums; your start-up time is reduced and you have an essentially seamless blend for the remainder of the application,” explains Cook.

EASE OF USE & APPLICATION = SPF MARKET GROWTH

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PROCESS CONTROL By correctly processing the chemicals, contractors are able to reduce their liability for off-ratio jobs, increase their reliability of SPF equipment, reduce their regulatory concerns of open chemicals, and improve their yields.

One of the biggest challenges that makes or breaks a spray foam contractor is their efficiency in the field. That said, whether you’re a 30-year veteran in the industry or a newbie on the first job, you’re only as good as the equipment you have to work with. The unfortunate nature of the beast is that there will be subpar spray applications. One might be taking place as you’re reading this, and that is one more bad egg that adds to the stigma of “bad spray foam.” However, the right system could turn those wrongs into rights with haste. The less headaches and troubleshooting involved within the contents of your spray rig, the more successful and profitable you can potentially be. A spray foam application system that virtually does most of the work for you is three-quarters of the battle.

Akurate Dynamics aims to take ease of application to the next level with a chemical processing system that yields consistent, quality spray applications attached to a strong return on investment. And so, they furnished the Delta CPS with a generator that runs on less power than the common displacement system, and that means the weight of the unit and operating expenses are reduced. Additionally, they eliminated pulsation reaching the spray gun (commonly seen with average displacement systems) by utilizing a rotary screw compressor, which provides stability that allows for a consistent spray pattern diffusion and ease of use and application. But perhaps Delta CPS’ strongest feature in terms of consistency and higher yields is its control of chemical viscosity, which is achieved by its automated ability to control hose heat and dynamic pressure.

“We can impact the growth of the industry and improve the reputation of SPF by providing the most reliable chemical processing system to date; this system will allow spray foam contractors to run a good operation to where they are able to spray more every day – their costs will come down and their profits will go up,” affirms Cook. “With the Delta CPS controlling viscosity all the way to the end of the gun, correct atomization occurs resulting in maximum yield of the chemical products. Virtually, the operator only needs to worry about the temperature he set his spray gun to, how much chemical he wants to come out of the gun, and what is the pressure that he wants to spray. Beyond this, the machine does the rest.”  •

CONTACT AKURATE DYNAMICS, INC.

Direct any questions about the Delta Chemical Processing System to Akurate Dynamics:
Phone: 832-672-5665
Website: www.akuratedynamics.com

Photos courtesy of Akurate Dynamics, Inc.