3 reasons to move from a manual to an automated spray coating process

This is a question most often asked by smaller companies employing no more than a dozen staff. As the market becomes more demanding in terms of lead times and quality standards, manual spray coating techniques have a number of drawbacks.
You may not realise, but transfer efficiency is no higher than 25% and often the pieces need to be re-sprayed when the quality achieved is not in line with the customer’s expectations. Such issues are putting pressure on small outfits using manual labour and the pressure is felt not only by the owners, but also by the operators themselves.
Reworking products also takes time, not to mention the cost of extra lacquer and labour, and it leads to inevitably longer delivery times, something your customers will not appreciate. Reworks can be avoided.
Switching from manual to automated spray coating may seem like a step into the unknown for some companies, but the return on investment will soon be felt. An initial investment with some reorganisation of floorspace will be necessary. One or two operators will need to learn a few basics before being able to program the equipment, but once this is done, they will only need to oversee the process, load and unload workpieces and keep to schedule. What you will notice is that coating quality consistency will no longer depend on which operator is spraying, how much coffee he had or whether he is spraying well at 9 a.m. or spraying as best he can at 5 p.m. – it makes a difference!

How will an automatic spray coating machine improve all this?

• Firstly, you will obtain the same quality without any variations, so once it is satisfactory, you just need to push a button and let the machine accomplish the rest.
• Secondly, you will save on lacquer because transfer efficiency will increase significantly, in some instances reaching more than twice as much compared to manual spray coating.
• Thirdly, your production efficiency will increase and consequently delivery times will be reduced, so you can accept more business and maybe extend your customer base.
• Fourthly, labour costs can be cut because you only need one operator to manage the programming and supervision of the equipment, as well as loading and unloading the pieces.

So what are the 3 reasons?

Simple, we have created several spray coating solutions, but many of these are sophisticated machines handling complex geometries, processing on flatbed or overhead lines and using special anthropomorphic robots.
But there are 3 solutions which represent a perfect first step into the world of automated spray coating:

• Prima
• Mito
• Easy

Before you make a choice, there are a few things to consider. Base your decision on the goals you aim to achieve, not on your current capacity. Consider your need to make frequent colour changes; in this case you should opt for Prima, an excellent solution when dealing with frequent colour changes or several small batches. Mito can be fitted with one central or two lateral arms, and is good for small to medium outputs. Easy will be suitable for handling medium to large volumes and can be fitted with a number of optional features.

If you are keen to learn more about moving from manual to automated spray coating, our experts will be happy to personalise the solution according to your real needs.
So if you are ready to explore the new potential awaiting you and your business, contact us for more details.

What’s so special about profile wrapping?

Profile wrapping is not only a relatively economic process, it also allows for high output and enables you to offer products with a large range of surfaces including veneer and high-gloss decorations. Running your own profile wrapping line instead of buying ready-made bars offers you a lot of flexibility.

What do you need to start profile wrapping?

Obviously you need a profile wrapping line, but also skilled staff and consumable products like adhesive, foil and maybe primer. The length and width of the line – and thus the space it will occupy - depend on the dimensions and shapes of the work pieces you would like to wrap. Also, the machine will need electric energy and compressed air.

What does a profile wrapping line look like?

Usually, a profile wrapping line consists of an entry zone, a glue application and a wrapping zone. Then, there are additional components like in- and outfeed systems, premelters and separating systems.

Where do I find further information?

We recommend reading the White Paper which gives a comprehensive overview of technical terms and the composition of a profile wrapping line. Any questions left? Contact us. Our Sales Engineers will be happy to help you.

Who knows a company that won’t want to cut costs wherever possible, saving money directly from lower consumption and indirectly by saving time on repetitive procedures?

A patented paint recovery system which cleans your equipment reduces the amount of paint wasted and also the quantity of detergent needed to clean. It also saves time when changing from one production run to the next when colour changeovers are involved.

A wider belt under the painting surface collects excess paint during spraying, thereby protecting the machine's filters. A counter-rotating roller also recovers paint while the machine is working, so no downtime is necessary. Better belt condition leads to longer belt life and fewer stoppages to replace them.

The amount of detergent needed is reduced to a minimum. Less than 50 litres of detergent per shift are required on average to perform cleaning operations.

Take a look at this short video to see how the system works and contact us if you desire more detailed information. Our spray coating machines can be equipped with this device.

This is a question that comes and goes, usually getting a negative response because saving money inevitably means a compromise which reduces quality. But if your business profits rely on cutting overheads, especially in the form of electricity, or if you can obtain incentives by implementing sustainable technologies, you cannot stand still, you need to make a choice. When you’ve already opted for quality, you will be using a spraying robot such as iBotic. Thinking of saving money would probably lead you to consider reverting to an oscillating spray coater or even hand-coating the pieces in a spraying booth. Neither options will conserve the finished quality of the spraying robot, so where do you look?

An integrated finishing line needs to be managed in an integrated way to make it as efficient as possible. This is one of the reasons we developed cTracker, a powerful software tool which allows companies to manage complex processes involving multiple machines from one single point.

Now featuring standard, off-the-shelf components (CPU for each machine, 5” and 12” HMI, six 3-fase inverter types) which can be replaced immediately if necessary, our machines and most 3^rd party equipment can be connected via an Ethernet network to a PLC and an industrial PC with a 21” multitouch screen enabling immediate intervention anywhere on the line.

Exactly what can be done with cTracker?

First of all, you can enter and adjust all recipes from a single monitor. Secondly, you can manage individual machine parameters from that same monitor and any alarms coming from the machines on your finishing line will appear on the monitor. Basically you won’t need to move from machine to machine or run up and down the line to keep track of production and maintain the highest efficiency on your line.

Single piece tracking capabilities will help speed up production. Each time a tracked piece from a batch is identified at a certain point on the line (usually when the colour or thickness changes) the machine automatically implements the dedicated parameters without needing to re-program or stop the line.

Featuring cLink, the data collected by cTracker can be fed into your ERP, stored and used to improve processing efficiencies or to forecast production schedules.

cTracker also enables remote support services, using a VPN tunnel which is certified IEC 62443 for additional cybersecurity.

If you need more information about cTracker or any of our cutting-edge software and Industry 4.0 solutions, please contact us.

✓ 25 years of LAB experience
✓ 3000 square metres of space
✓ 85 machines

Let us start right here with the first chapter of the experience gathered by our team of finishing professionals in the Laboratory where our technicians, customers and paint suppliers carry out the tests, pre-empting industrial tests, on the solutions we provide to the market, trying out the processes and experimenting with new technologies.

Over the coming weeks, LAB Manager Eduard Raffini who has been in charge of the LAB team since 1995 and handles both the machines and the lines, will tell us the best ways to run tests.

We will take a close look at the phases of each process, from the preparation of the substrates (sanding, rusticating, brushing), to the adhesion treatments (flaming or primers, impregnations and base coats, sanding), up to the glossy, opaque or textured finishes, with a porous effect or deep matt.

There is a constant made up of variables:
▷ Each customer has specific needs
▷ Each customer has their own products
▷ Each customer has their own processes

Everyone wants to improve the business, evaluating finishing technologies, different machines, more efficient processes. It is the passion that drives time and time again to reach the best solution.

Contact us and arrange a visit to the LAB. 

Eduard Raffini