An original equipment manufacturer (OEM) specializing in interior automotive components faced exorbitant expenses due to the daily replacement of its primary filter in a paint booth filtration system. Recognizing the need for a more cost-efficient approach, OTC Industrial Technologies offered a comprehensive, innovative solution that substantially reduced both material and labor costs.
A prominent automotive manufacturer relied on a finishing system in which the primary filter required daily replacement. In addition, the secondary pocket filters, which were considerably more expensive, needed replacement every two weeks. As material costs continued to escalate, the associated expenses and labor needed to maintain these filters became unsustainable. The manufacturer urgently sought a cost-effective strategy that would lessen the time and resources dedicated to filter changes to alleviate the strain on its operations.
Rather than hastily proposing the least expensive filter on the market, OTC adopted a methodical approach that involved a more strategic filtration plan to mitigate these challenges. OTC proposed conducting an in-depth investigation to identify a solution that would be both more cost-effective and more operationally efficient.
The team thoroughly reviewed the specific filter requirements and cost factors that underpinned the project to ensure that any proposed system would align with the manufacturer’s unique operational needs.
Leveraging their experience with similar filtration applications, OTC identified a three-piece filter solution known for its superior efficiency. One of the primary advantages of this design is that only the central section of the filter needs replacement, significantly reducing overall maintenance demands.
To verify effectiveness, OTC conducted an airflow study using the existing filters to establish a performance baseline. Once this data was collected, the manufacturer received three alternative filter options and corresponding performance targets. After the test filters were installed, OTC executed a second airflow study. These findings supplied the manufacturer with crucial data about the performance of each proposed filter solution.
Following these evaluations, the manufacturer embarked on a month-long trial with the recommended filters, solidifying their confidence in the new filtration system’s efficacy.
By transitioning to the OTC-recommended filters, the manufacturer achieved nearly a 40% reduction in its overall filter costs compared to its prior filtration strategy.
Furthermore, it experienced a substantial decrease in the labor required for filter upkeep, resolving the previous burden of frequent maintenance. This new solution has proven far more effective and efficient than the manufacturer’s earlier, less strategic approach.
Impressed by these results, the manufacturer’s leadership has enlisted OTC to conduct similar assessments on other systems and processes throughout the facility, illustrating both the trust and value garnered by OTC’s consultative, data-driven approach.
Learn more about OTC’s filter audits and explore the potential cost savings for your company.