Innovations
Published: July 17, 2024
Innovations
Published: July 17, 2024

PPG PLUG & SPRAY System for Plastering Has Labor, Waste Savings in the Box

PPG PLUG & SPRAY-systemet til spartling med sprøjte har arbejds- og affaldsbesparelser i kassen

Inspired by a bag of wine in a box, the PPG PLUG & SPRAY™ system reduces the time painters spend plastering by up to 50% as well as related plastic waste by 85% compared to traditional methods. We introduced the innovative solution in Denmark in 2024.

Inspiration Converges with Innovation

While visiting our customers at project sites, Morten Karlsen, regional sales and business development manager for our Architectural Coatings business in Denmark, observed how time- and labor-intensive plastering on a large scale is for painters. These projects typically involve one worker manually filling and carrying numerous containers holding up to 20 kilograms of plaster while another applies it to the wall.

Handling all those containers, which often are at the weight limit of what you can legally lift at work in Denmark, is physically hard and time-consuming. We began looking at how to overcome this challenge while also delivering sustainable benefits.
Morten Karlsen

The solution required both inspiration and innovation. Knud Schioldan, service technician and Morten’s colleague, saw a three-liter bag of wine in a box and immediately thought “Why can’t we fill a bag with plaster, place it in a box and use a sprayer to apply the plaster to the walls?”

It was possible, as the previously introduced bag-in-a-box concept for our DYRUP™ paint brand showed. The challenge was scaling up the solution to handle 500 liters of plaster, which has a much thicker viscosity than paint or wine.

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Efficient and Sustainable

Although it looks simple, the easy-to-use Plug & Spray system involves a number of high-tech components.

A specially designed tear-shaped bag is packed in a reinforced cardboard box, which is secured to a standard EU pallet that can be moved with a pallet lifter. The system connects to most professional spraying systems through an included adapter.

The Plug & Spray system requires only one box and one painter for a single job. In addition to halving labor requirements, it:

  • Reduces the time spent on plastering up to 50%;

  • Minimizes the risk of spills and foreign objects getting into the plaster, improving the work process and reducing downtime and costly repairs;

  • Delivers improved ergonomics by eliminating the manual lifting of heavy bags; and

  • Reduces plastic waste by 85% by going from 40 bags made of nearly 25 square meters of plastic to one bag made of only 4 square meters of plastic. The Plug & Spray system’s cardboard box also can be recycled.

Debut Excites Industry

The system debuted at the Nyborg Fair, Denmark’s biggest industry event for painters, in January 2024. It quickly generated significant interest and excitement among attendees.

I’ve been part of the Nyborg Fair for more than 15 years, and this has been our biggest success yet. EVERYONE welcomed the Plug & Spray system. Our customers could see its obvious benefits.
Morten Karlsen

Morten, Knud and their colleagues are already looking to take the Plug & Spray system across Denmark’s borders to make plastering work easier, efficient and more sustainable around the world.

Get in touch with our Danish team at https://ppgpro.dk/produkter/plug-and-spray/

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Inspireret af en flaske vin i bag-in-box reducerer PPG PLUG & SPRAY™-systemet den tid, malerne bruger på at spartle, med op til 50 % og det tilhørende plastaffald med 85 % i forhold til traditionelle metoder. Vi introducerede den innovative løsning i Danmark i 2024.

Inspiration mødes med innovation

Da Morten Karlsen, regional salgs- og forretningsudviklingschef for vores Architectural Coatings-forretning i Danmark, besøgte vores kunder på projektsteder, observerede han, hvor tids- og arbejdskrævende spartling i stor skala er for malere. Disse projekter involverer typisk, at en medarbejder manuelt fylder spartel i et kar og bærer adskillige sække med op til 20 kg puds, mens en anden påfører det på væggen.

Det er fysisk hårdt og tidskrævende at håndtere alle de sække, som ofte ligger på vægtgrænsen for, hvad man lovligt kan løfte på arbejde i Danmark. Vi begyndte at se på, hvordan vi kunne overvinde denne udfordring og samtidig levere bæredygtige fordele.
Morten Karlsen

Løsningen krævede både inspiration og innovation. Knud Schioldan, servicetekniker og Mortens kollega, så på en treliters bag-in-box vin og tænkte straks: »Hvorfor kan vi ikke fylde en pose med spartel, lægge den i en kasse og bruge en sprøjte til at påføre spartlen på væggene?«

Det var muligt, som det tidligere introducerede bag-in-box-koncept for vores DYRUP™-malingsmærke viste. Udfordringen var at opskalere løsningen til at håndtere 500 liter spartel, som har en meget tykkere viskositet end maling eller vin.

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Effektiv og bæredygtig

Selv om det ser enkelt ud, involverer det brugervenlige Plug & Spray-system en række højteknologiske komponenter.

En specialdesignet dråbeformet pose er pakket i en forstærket papkasse, som er fastgjort til en standard EU-palle, der kan flyttes med en palleløfter. Systemet kobles til de fleste professionelle sprøjtesystemer via en medfølgende adapter.

Plug & Spray-systemet kræver kun én kasse og én maler til et enkelt job. Udover at halvere behovet for arbejdskraft:

  • Reducerer den tid, der bruges på spartling, med op til 50 %;

  • Minimerer risikoen for, at der kommer fremmedlegemer i spartlen, hvilket forbedrer arbejdsprocessen og reducerer nedetid, spild og dyre reparationer;

  • Giver forbedret ergonomi ved at eliminere manuelle løft af tunge sække; og

  • Reducerer plastaffald med 85 % ved at gå fra 40 poser med næsten 25 kvadratmeter plast til én pose med kun 4 kvadratmeter plast. Plug & Spray-systemets papkasse kan også genbruges.

Debut begejstrer industrien

Systemet debuterede på Nyborgmessen, Danmarks største branchebegivenhed for malere, i januar 2024. Det skabte hurtigt stor interesse og begejstring blandt deltagerne.

Jeg har været en del af Nyborg-messen i mere end 15 år, og dette har været vores hidtil største succes. ALLE tog godt imod Plug & Spray-systemet. Vores kunder kunne se de åbenlyse fordele.
Morten Karlsen

Morten, Knud og deres kolleger er allerede i gang med at tage Plug & Spray-systemet med ud over Danmarks grænser for at gøre spartelarbejde lettere, mere effektivt og mere bæredygtigt i hele verden.

Kontakt vores danske team på https://ppgpro.dk/produkter/plug-and-spray

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