Pallet coating waste recovery system

A self-contained unit having a system for recovering polymer overspray from a pallet coating process comprising:

• a common enclosure having at least four walls, a ceiling and a floor;
• a collection tank located below the floor of the common enclosure;
• a roof platform located above the ceiling of the common enclosure;
• at a plurality of spray booths within the common enclosure having a waterfall wall with liquid flowing down a face of the waterfall wall to the collection tank;
• a workpiece holder within a plurality of spray booths for holding a workpiece, wherein the waterfall wall is positioned on a first side of the workpiece holder;
• a spray applicator within each of the a plurality of spray booths for spraying a polymer onto a workpiece positioned on the workpiece holder, wherein an overspray of polymer from the spray applicator travels past the workpiece and contacts the liquid of the waterfall wall and is transferred to the collection tank;
• a hydrocyclone pump connected to a second outlet of the collection tank;
• a hydrocyclone for receiving a portion of the overspray mixture that the hydrocyclone pump moves from the second outlet of the collection tank to an inlet of the hydrocyclone, wherein the hydrocyclone separates the portion of the overspray mixture into a first solid rich mixture that is removed from a first outlet of the hydrocyclone and the liquid that is removed from the second outlet of the hydrocyclone and sent back to an inlet of the waterfall wall;
• a consolidation tank pump connected to a first outlet of the collection tank;
• a consolidation tank connected to the consolidation tank pump for receiving a portion of the overspray mixture that the consolidation tank pump moves from the second outlet of the collection tank through an inlet of the consolidation tank, wherein a portion of the polymer in the overspray mixture will float to the surface of the consolidation tank creating a second solid rich mixture that is removed from the consolidation tank and a portion of the polymer in the overspray mixture will sink to the bottom of the consolidation tank creating a third solid rich mixture that is removed from the consolidation tank;
• a cone bottom tank for receiving the first solid rich mixture, the second solid rich mixture and the third solid rich mixture, that are combined to form a cone tank mixture that contains the polymer and the liquid, where the polymer is in greater concentration than the liquid, wherein the cone bottom tank has an outlet for removing the cone tank mixture;
• and
• a pressure filter having an inlet for receiving the cone tank mixture and a drying chamber for holding the cone tank mixture, wherein the drying chamber has a screen with media for capturing polymer in the cone tank mixture as pressurized air is forced through the cone tank mixture to separate the cone tank mixture into a dried polymer cake and a return liquid that is transferred through a liquid outlet of the pressure filter back to the collection tank, wherein the dried polymer cake is removed through a chute to a hopper.