Finding a way to match the finishing quality of your flat surface with the edge, especially when the market is looking for rounded edges and flat surfaces as part of the latest furniture trends, means you need to consider using the same paint and the same technique. Until today, this was just theoretical, but since we introduced Smartvacuum to combine with Smartedge, our vacuum coating solution for edges, it is now a reality.

Vacuum coating: sustainable and cost-efficient

Depending on the production volumes, with vacuum application technologies there are different solutions to coat the surface and edge of a panel. Outputs up to 1500 cabinet doors/shift can be handled with an island-type process dealing with:

• melamine sanding
• flat surface coating (Smartvacuum)
• edge coating (Smartedge)
• sanding prior to finishing

In-line processes are better for outputs exceeding 3000 cabinet doors/shift and can be either:

• melamine sanding
• panel surfaces coated in the Smartvacuum area
• panel edges coated in a 2-step process with Smartedge
• sanding prior to finishing

or for 6000 cabinet doors/shift as follows:

• melamine sanding
• in-line flat surface coating (Smartvacuum)
• all 4 panel edges coated using Smartedge
• sanding prior to finishing

Both Smartvacuum and Smartedge use 100% UV acrylic paints, avoiding release of solvents into the atmosphere. Processing times are reduced compared to alternative application technologies and less space is taken up by these machines.

Focusing on the edge coating process, we have developed patented solutions for Smartedge which are unrivalled on the market. EDGE&GO enables line operators to switch from one edge geometry/thickness to the next in no more than 15 seconds.

The dual function sanding unit for vertical corners with a radius and the flat section of a J-pull ensures compliance with the original radius and sanding of the excess product at the leading and trailing end of the handle.

The paint removal and panel cleaning unit seals the melamine between the flat part and the edge, recovers excess applied product and creates a perfectly flat panel surface. This prolongs the life of the abrasive paper in contact sanding machines, as wear is homogeneous over the whole surface.

The winning duo

The combination of Smartvacuum and Smartedge finally allows companies to streamline their coating process using the same technique and delivering the same top quality all round. It avoids pollution compared to spraying lacquers with solvents, it speeds up the process, reducing the handling necessities and, above all, cuts costs significantly.

Learn more about Smartvacuum in this webinar

Whereas elliptical spraying techniques ensured high speeds and large volumes in the past, more recent reciprocating solutions have outpaced machines based on a rotary distribution system, especially in face of smaller production batches required by today’s market. Reliability was also an issue which played against the choice of this technology, but today’s redesigned Elispray features new, patented solutions that enable extremely high speeds, excellent transfer efficiency, reliability and reduced lacquer consumption by up to 20%.

Elliptical spray coating: superior transfer efficiency

Several factors have increased the transfer efficiency of the new Elispray. Combining a high-performance spraying booth with high-speed distribution, we have achieved excellent results. Innovations include:

• double plenum directs overspray where it is needed, settling gradually on the workpieces instead of being forced down
• belt surface has been increased to maximise overspray recovery
• new layout of suction areas interferes less with overspray
• guns operate at lower speeds than a reciprocating machine, making it possible to use lower feed pressures and waste less lacquer

Reliability ensures minimal maintenance downtime

Elispray features a patented product distribution system on the guns, eliminating aspects that undermined reliability in the past. A rinsing circuit also runs right next to the seals of the lacquer delivery circuit. Conveying water or solvent, it rinses, helps detect leakage points and reduces the working temperature of the joints thereby extending seal life.

The following benefits are obtained:

• minimises defects and machine downtime caused by localised leakage
• critical machine components can be monitored while the machine is working to avoid unproductive stoppages
• allows companies to plan maintenance sessions without needing to react to problems which disrupt production

Discover more on Elispray in this webinar

How can vacuum coating technology improve primer application on panels?

Industry professionals know that primer application on wooden panels is typically carried out using one of three methods: roller coating, spray coating or curtain coating. Each approach has its own pros and cons, depending on various factors.

The introduction of vacuum technology helps overcome many of the limitations of traditional systems—without necessarily replacing them entirely—offering new opportunities and benefits, especially for manufacturers of cabinet doors, panels, and bathroom furniture.

How does vacuum coating technology work in primer application on wooden panels?

Vacuum coating technology creates a low-pressure environment to improve the primer application process, ensuring uniform and efficient coating.

During this process, panels are placed inside a vacuum chamber, where air is extracted to lower the pressure around the surfaces. The reduced pressure allows lacquers and primers to penetrate deeper into the wood grain, improving adhesion and minimising the risk of bubbles or imperfections.

Additionally, vacuum technology plays a crucial role in eliminating air bubbles that can cause uneven finishes. This results in a smoother, more uniform coating that enhances both the appearance and durability of the finished product.

THE MOST ADVANCED FINISHING SOLUTIONS

The advantages of vacuum primer application on panels

Any flat panel made of wood or wood-based materials, including those with rounded edges, can be coated using vacuum technology.

This makes it an ideal solution for manufacturers aiming for uniform finishes while minimising imperfections and achieving extremely smooth surfaces. The vacuum process takes place in a controlled environment, reducing the risk of dust contamination. This is the key to higher precision and longer-lasting products.

Compared to spray coating, vacuum coating also results in faster drying times, enabling quicker production cycles and reducing material waste. This innovation not only improves the aesthetic quality of panels, but also improves the operational efficiency of production processes.

The result? Perfectly finished surfaces with minimal material waste and much better final quality.

Smartvacuum: Cefla Finishing’s vacuum coating technology in detail

Given the advantages of vacuum technology, Cefla Finishing has developed a user-friendly solution for processing flat panels with rounded edges, J-Pull versions, and panels with ABS edges.

Smartvacuum is a machine capable of applying 100% UV acrylic lacquer in a single pass, without any physical contact between the application head and the substrate. Thanks to vacuum technology, it deposits between 90 and 140 g/m² of product with extreme precision and uniformity, avoiding build-ups on any part of the panel.

The flash-off phase takes place after primer application and before final drying in a UV-R oven.

The use of 100% solid UV products makes the process more sustainable, and the finish remains more stable over time compared to polyurethane or polyester-based products, also requiring shorter drying times.

A complementary solution to other application techniques

As mentioned, vacuum technology offers numerous advantages over other finishing methods, but this does not mean it should be seen as an exclusive alternative to existing solutions. To truly appreciate its benefits, companies should evaluate their traditional finishing lines and determine the best integration between existing machinery and vacuum technology.

Roller coating lines

Roller coating is one of the most widely used surface finishing techniques for flat panels. The process typically involves:

• Substrate sanding
• Primer application for adhesion
• Three layers of primer applied with single and double application rollers, with intermediate gelling
• Final drying
• Sanding of the primer coat, followed by finishing

Curtain coating lines

Curtain coating is performed using machines called curtain coaters. These systems utilise liquid coatings that form a curtain of lacquer that falls onto the moving panel in a uniform fashion, allowing even coating application. The steps typically include:

• Substrate sanding
• Primer application for adhesion
• UV gelling
• UV primer application using a curtain coater and flash-off tunnel
• Drying
• Sanding of the primer coat, followed by finishing
  
  

Spray coating lines

Spray coating lines use a closed-loop system for applying polyurethane or polyester-based primers in multiple layers on flat surfaces and edges. This set-up requires extended drying times, as panels must be stabilised at appropriate intervals before sanding and finishing.

Vacuum application technology: a comparative advantage

When correctly implemented alongside traditional techniques, vacuum technology enhances finishing processes, making them more efficient and sustainable.

The eco-friendly nature of 100% UV acrylic lacquers offers several advantages, reducing material consumption, costs, lead times, handling requirements and equipment footprint.

Additionally, when vacuum application is integrated with traditional methods:

•  Rounded corners are obtained directly using vacuum coating technology, meaning you only need to sand the flat surfaces after drying
•  Fewer machines required, meaning less cleaning and lower consumption
• Lower sanding costs and reduced material waste
•  Shorter lead times and greater production flexibility
• Reduced machine footprint
• Fewer process stages, minimising handling needs

By implementing Cefla Finishing’s Smartvacuum, the finishing line would consist of the following steps:

• Panel sanding
• Primer application and gelling
• Application of 90-140 g/m² of 100% UV product in a single pass
• 2-5 minutes of flash-off
• Drying in UV lamp ovens
• Sanding and matt/gloss finishing as needed, using other known coating techniques

Smartvacuum: the perfect partner for Smartedge

Smartvacuum works best when paired with another Cefla Finishing solution: Smartedge, a machine for edge coating, filling and sanding, configurable with modular options to meet different quality and productivity needs.

The coating application can be performed with a traditional vertical roller, a patented soft vertical roller that automatically adapts to edge shapes without the need for counter-shapes, or using vacuum technology.

Smartedge and Smartvacuum share both technique and lacquer. This ensures optimal continuity between the flat surface and the panel edge.

The result? A smoother finish compared to conventional application techniques, especially on panels with rounded edges. This reduces the number of steps required to process semi-finished products and, most importantly, helps achieve a high-quality final product.

LOOKING FOR THE PERFECT FINISHING LINE SOLUTION?

One of the key advantages involved in vacuum application technology is the degree of transfer efficiency achieved - almost 100% - meaning close control over lacquer consumption and very little waste – all adding up to significant savings while achieving superb coating quality.

Until recently, this technology was used for edges, in terms of coating, sealing or even waterproofing. Today, we have developed vacuum application solutions for flat panels as well as edges, which can be of all shapes and sizes.

Vacuum coating: flat panels

Manufacturers of cabinet doors, panels and bathroom furniture will welcome the recently released vacuum application machine, Smartvacuum. Any wood or wood-based flat panel can be coated using this technology, especially those with rounded edges.

Vacuum application avoids contact between the application head and the substrate. This enables clean, efficient processing using 100% UV acrylic paint in a single pass. Up to 140 g/sqm are deposited homogeneously, thereby avoiding product build-up on any sections of the panel. The process is simple, clean, eco-friendly and cost-efficient. Flash-off is performed after basecoat application and prior to the panel completing its drying in a UV-R oven. Using a 100% solid UV product, this makes it a relatively sustainable process and the coating is more stable over time compared to polyurethane or polyester-based products.

Vacuum application machines: edges

Vacuum application machines for edges have been around for longer, some of which combine sanding operations as a complete solution. We provide 3 different systems according to specific needs.

The perfect match for Smartvacuum is Smartedge, a machine which handles straight and shaped panel edges. The vacuum system will coat any type of edge as the application head adapts to each shape. When fitted with Edge & Go, consisting of an application head with interchangeable straight or shaped slats, changing from one edge shape to the next is accomplished without turning off the vacuum tower. In terms of speed, switching from a straight edge with a 3 mm radius to a J-Pull handle edge, for example, takes less than 15 seconds.

Smartvacuum and Smartedge use the same technique and the same lacquer. That makes it simple to achieve the best junction seam between the flat surface and the edge of the panel.

Sealing solutions

Sealing operations are performed to protect the integrity of a product by ensuring the edges are not vulnerable to humidity for example, something which compromises the durability of a panel or other item.

Vacuum systems for the sealing of edges include another machine in our range: Talent is a patented solution for the sealing of the shaped edges of laminated panels, coated with quick-drying water-based products for application on various types of material. Used as a sealing technique for items found in several sectors, including panels, mouldings, fibreglass ceiling panels, polycarbonate sheets, fibre cement tiles and many other materials used in the construction industry, Talent works with water-based coatings, also suitable for UV curing, 100% UV acrylic paints, sealants (wax, paraffin, glue).

Edge impregnation

A solution dedicated to sealing the edges of panels is required when the risk of water penetrating the panel is an issue. In certain instances, cabinet doors, but more frequently panels for flooring applications will need to have their edges well sealed so as to avoid quality decreasing over time. Hybrid implements a patented technique to impregnate the panel edge with a special UV polyurethane glue to protect against humidity and other harmful elements.

Contact us and discuss your needs with a finishing expert.

Roller coating technologies have evolved significantly over the last two decades and the recent introduction of a new soft application roller onto the finishing industry’s most advanced roller coating equipment, Smartcoater PRO, has brought about several benefits, enabling companies to achieve important savings especially with regard to the coating of raised panels, such as kitchen cabinet doors.

Smartcoater PRO is built with 4 screw jacks which ensure a rigid, stable structure for the application roller which applies constant, firm pressure to panels transiting through the machine. Thanks to the pneumatic floating system which can be integrated, the application head moves side to side, following irregularities and compensating for poorly calibrated flat panels. This enables coating consistency and reduces the chance of rejects if quality standards are not reached.

Featuring the latest innovation, a soft rubber application roller, Smartcoater PRO acquires even more interesting capabilities: roller coating raised panels.

The benefits, one by one

Apart from facilitating a continuous production flow without the need to stop for non-calibrated panels, in general terms there are numerous benefits ranging from production capacity and efficiency to reduced costs and environmental benefits.

Until recently, base coats and top coats were applied to raised panels using spray coating equipment. This usually means three-phase coating with sanding operations between the two base coats and manual intervention, loading and unloading at each step of the process.

Thanks to the soft roller on Smartcoater PRO, the coating process for raised panels is shortened. The ability to apply a base coat to grooves up to 10 mm in depth on a raised panel allows companies to install hybrid finishing lines made up of two roller coating stations and a spray coating machine for the top coat. Here are some of the many benefits:

• transfer efficiency on the roller coaters is superior, thereby reducing lacquer consumption
• absence of an intermediate sanding operation between base coats means lower operating costs, fewer abrasives, less manual labour connected with this operation
• with less lacquer consumption comes a drop in solvent consumption, leading to lower emissions as well as lower direct solvent costs
• fewer passes through the line – just 2 instead of 3 – limits the handling operations which in turn reduces the risks of damage to finished products
• fewer passes also speed up production and reduce lead times

Production speeds increase in all instances

Whereas base coats for a matt finish may only need one application layer on a roller coater, followed by the spray coater for the top coat, it is advisable to apply 2 layers of the base coat for a glossy finish. This is made possible by using two Smartcoaters in a row on the hybrid line. Whichever scenario, time is reduced either by reducing the number of base coats (matt finish) or implementing consecutive base coat application which applies a second layer prior to the top coat.

Roller coating: sustainability and savings

Of course, it takes more than a soft rubber roller to generate significant savings and increase the overall sustainability of the coating process. The engineering skills and laboratory tests run to investigate all production scenarios have led to a system which is unmatched in terms of its quality and sustainability.

Savings on lacquer consumption range between 3 and 25% in terms of the quantity used (consequently affecting solvent quantity as well) and this represents anything up to 1 euro per square metre.

Less solvent means lower costs, but also leads to a healthier working environment for operators and fewer worries about harmful emissions affecting the planet.

The new level of efficiency also reduces the workload to employees with fewer handling necessities involved.

In conclusion, the soft roller increases production capacity, reduces processing times, saves money and respects the environment.

So soft that it’s hard to beat!

Find out more about our roller coating solutions

If it weren’t for over 100 lines installed worldwide using our Laser Roller, it would be acceptable to assume that the best way to achieve a glossy surface finish was either using a curtain coater or a spray coating machine. But when we introduced the laser-engraved application roller and fitted it (when required) to our roller coater range, the results revealed a number of benefits. Since then, our customers using the Laser Roller can boast coating quality and above all sustainability.

Benefits of the Laser Roller for high-gloss finishes

Clearly a solution exclusively for flat panels, but of any size according to the roller coating equipment it is fitted to, the Laser Roller applies a large quantity of lacquer (up to 45 g/sqm) without leaving any traces or defects that are found typically on roller coated surfaces. Compared to spray coaters or curtain coaters, the main advantage is that with a Laser Roller you are making a sustainable choice. This technique allows you to use 100% acrylic UV lacquers with only solid residue.

We also do exactly the opposite, so if you are interested in a deep matt finish, please visit this page for full details.

Which substrates can I coat with a Laser Roller?

In addition to wood and its derivatives, substrate materials that are coated using a Laser Roller include PMMA, glass and fibre cement. The high-gloss finish enhances the aesthetic qualities of any substrate and can be achieved with consistent quality and with less environmental impact than most other coating techniques.

Laser Roller – the machine dedicated to high-gloss finishes

More than an engraved application roller, the Laser Roller is also a complete roller coating machine which can be integrated into a finishing line to achieve specifically high-gloss surface finishing. Ensuring top performance, the quality obtained on the Laser Roller equipment is consistently in line with the most demanding objectives for high-gloss finishes.

Use our expertise to solve your needs

Cefla Finishing has developed countless solutions using roller coating technologies. These range from innovative roller coating equipment to the Smartcoater PRO which can be equipped to handle slightly raised panels as well as poorly calibrated panels. Together with the laser-engraved application roller, we also fit optional systems to adapt the machinery and the line to your real needs, taking into account your objectives and the products you are handling.

You can even fix an appointment with one of our roller coating experts and visit our laboratory to run tests using your lacquers and your products.

Contact us and our team will examine your requirement.