How to Improve Finishes for Household Appliances

How important are finishes for household appliances? More than one might imagine. Many actually underestimate this aspect. But the truth is that the objects we use every day—such as televisions, washing machines and refrigerators—owe many of their qualities to advanced finishing processes.

High-quality finishes and attractive, durable household appliances form an inseparable combination. Coating solutions make the difference, creating surfaces that are pleasant to the touch, long-lasting and visually impeccable, yet also capable of adapting to modern design requirements. All this without ever compromising functionality.

Why are appliance finishes essential?

Let us consider the plastic parts forming essential elements of everyday objects, such as the bezel of an ultra-flat TV, the handles of refrigerators and ovens, or the porthole of a washing machine.

These are all components with two features in common: they must be aesthetically pleasing and, more importantly, safe and functional.

From this perspective—beyond basic engineering and design—the type of finish makes all the difference in the daily user experience. Handling, grip, perceived solidity and quality, and even the sense of seeing and touching something familiar and pleasant: all derive from the care with which finishes are applied to household appliances.

Objects that withstand the test of time can be recognised immediately. And it is precisely this feeling that most attracts consumers when making their purchasing decisions.

The best technologies for appliance coating

The only way to achieve such results is to rely on advanced spray-coating systems: composite and integrated finishing lines equipped with machinery capable of ensuring consistent quality at every stage of the process.

Cefla Finishing offers two dedicated solutions—iBotic and iGiotto App—which can also be integrated into existing coating lines.

iBotic is a Cartesian spraying robot offering new functionalities to optimise coating operations for appliance components, with tangible economic and production benefits. The machine is ideal for companies dealing with increasing customisation demands, requiring frequent colour changes. What truly sets iBotic apart is its ability to work simultaneously on parts of different shapes and thicknesses, both at a standstill and in motion, in tracking mode, and to autonomously generate ideal spray trajectories through a 2D or 3D reading system.

iGiotto App is the automatic system that combines state-of-the-art coating technologies with the high performance of six-axis anthropomorphic robots. Equipped with cVision 3D, iGiottoApp can accurately detect the position, size and shape of incoming items, autonomously generating spray paths even for heterogeneous pieces with pronounced three-dimensional shapes. In short, everything needed to achieve maximum quality for every appliance component.

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Appliance finishes: every component requires its own treatment

Finishing household appliances may require different treatments to make the product more attractive to the end customer.

Take, for example, washing machine portholes: the part to be coated is the round chrome section surrounding the transparent window.

Chroming requires application on a prepared surface that covers defects and stresses typical of plastic parts produced through injection moulding. These defects—even when small—become highly visible once chrome is applied, especially when deposited in thin layers via PVD (Physical Vapour Deposition). Coating the component prior to chroming isolates the plastic substrate and covers imperfections, achieving significantly better aesthetic results and, above all, consistent long-term quality.

Base coating as preparation for subsequent chroming can be carried out on a Cefla line composed of cleaning and deionisation systems, an Easy-type sprayer, an Ecogel tunnel for paint levelling and a UV oven for final curing.

Cefla also provides all systems needed to prevent surface contamination from airborne dust, ensuring high-quality results.

The advantages of customised coating solutions

At Cefla Finishing, we know that every plant has specific operational needs and production philosophies that evolve over time, beyond the technical parameters required to properly process a given component.

This is why we have developed a modular range of coating solutions. For us, modularity is synonymous with personalisation: machinery and software can be integrated with maximum ease; existing lines can be modified simply by replacing or adding machines to completely change the process, increase productivity, handle batches of different sizes compared to the current plant, or introduce new coating cycles. This allows appliance manufacturers—operating in an increasingly dynamic market—to remain agile and responsive to customer demands.

Cefla: the ideal partner to optimise appliance finishing processes

It should now be clear that finishes for household appliances represent a key element in combining aesthetics and durability, enhancing perceived product quality.

By offering cutting-edge technologies—from reciprocating spray systems like Mito and Easy to robots such as iBotic and iGiottoApp—Cefla Finishing stands out as the ideal partner for implementing reliable, customised coating solutions for household appliances.

Contact us to learn how to continuously improve your finishing process: our experts are ready to interpret your needs and work with your technicians to develop a tailored solution.

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Finishing has always been an essential part of the automotive component production cycle. The application of lacquers and protective layers ensure that sheet metal, plastic inserts and gaskets perform to their full potential, giving the vehicle outstanding visual appeal and ensuring parts are durable and high-performance regardless of the material used to make them.

Needless to say, a wide range of applications and technologies are used to manufacture automotive components. They vary according to the purpose for which the various parts are designed, but they all share the same need: they must be made and coated quickly and efficiently, without ever compromising quality, especially as regards surface finishes. This article explores the tools and processes that can be used to maximise results and also takes a look at the most ground-breaking methods.

Which finishing processes are used to produce automotive components?

Whatever the type of treated part - bodywork sheeting, gaskets, plastic inserts or mechanical components - an automotive component production line involves finishing processes of varying complexity. For example, finishing vehicle interior parts is usually a 3-stage process that might need to be repeated to achieve the desired final result.

Pre-treatment

The first step is pre-treatment. This involves cleaning and preparing the surface of the component. Popular techniques include deionization and micro-cleaning with plasma flaming.

Deionization involves blowing in ionized air and extraction to eliminate the static electricity: this is essential as it stops dust settling on the piece before coating. In addition to these technologies, Cefla Finishing has designed and developed the Mito CO2 cleaning station - which has a carbon dioxide snow cleaning surface preparation function - to help automotive component manufacturers perform this task to perfection. This solution is especially recommended for vehicle interior parts: approximately 90% of such products have, in fact, a shiny ‘piano black’ finish of the highest quality.

Plasma applications are particularly useful for reducing surface tension. This facilitates lacquer adhesion and flow.

Moreover, flaming also improves adhesion on certain tricky materials and allows better wetting of liquids on smooth parts, minimising surface tension (which reduces piece wettability, making it difficult to coat).

Coating

The second step is coating. This involves applying primer, lacquers and any other coats of specific materials needed to perfect the finish. In this specific area, Cefla Finishing offers a vast range of solutions.

These span from the Prima oscillating spray coater, a machine for the continuous spraying of raised panels of any type, to Mito, the P and B versions of which also provide dry filtration, paper/belt conveying and overspray elimination.

The iBotic machines are advanced robots with a sophisticated set of axes that ensure unrivalled productivity and absolute precision.

Another jewel in the Cefla crown is the six-axis articulated iGiotto robot: this innovative integrated system for the automatic spraying of small-to-medium lots features the best vision and spraying technologies, applying them to large Cartesian dimensions.

Drying or flash-off

The final phase is drying. This aims to harden the applied coatings by evaporating the thinners and subsequently curing the resin contained in the lacquer. Drying usually takes place in ovens (often arranged sequentially along the finishing line in different configurations), cooling tunnels and hot air storage modules. The term ‘flash-off’ refers to a drying process that does not result in complete hardening of the lacquer so that the next layer can adhere better.

With the Ecogel line, Cefla Finishing provides laminar-air ovens with a slat or belt conveyor. In their combined (air/UV lamp) configuration, these machines are perfect for evaporating solvents from lacquers quickly, before they’re dried with UV rays.

Moving on to drum ovens, the Aquadry line is designed for companies that want fast flash-off and drying processes. What’s more, the technology associated with this type of solution constitutes the most efficient drying system for water-based dyes and lacquers. The Aquadry RLA range, instead, consists of drum cooling tunnels with high-speed air blades, with a belt or slat conveyor. The architecture is highly effective thanks to the high levels of heat exchange that stem from the high air speed.

Then there’s PIEFFE, the flexible multi-level hot air storage module designed for flash-off and/or drying cycles with laminar-flow hot air. Hold times vary according to the speed of the finishing line and the number of trays.

Completing the range are the Omnidry Rack and Belt vertical ovens - configured to minimise the required floor space and ensure excellent capacity - and tunnel ovens with UV irradiation for raised panels.

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How to select the right type of finish

Choosing the right finish for the various types of automotive component means taking into consideration a wide range of factors: the material used to make the part, the setting it’s likely to be used in, plus the technical and aesthetic requirements of the vehicle on which it’s fitted.

Hence the need for a partner who does not have an excessively vertical approach to the functional-technological aspects of finishing processes but, rather, one who also knows how to assess the aims of the process and come up with properly tailored solutions.

Finishing technologies for automotive components

Of course, the technologies themselves are fundamental. However, to obtain an excellent result it’s equally essential to know how best to combine them according to the type of material to be treated and, above all, the component to be produced. That’s why Cefla Finishing goes beyond the design and development of efficient, precision machines to focus on consultancy.

For example, we provided a German customer - who needed to set up a new coating line as part of their car dashboard/console production process - with a solution tailored to their stated needs: the components produced by the new line would have to be completely defect-free as, once ready, they would be shipped directly to the vehicle assembly lines.

To deliver the required performance, then, the line was configured as follows:

1. Line loading with manual cleaning and air-jet/deionization
2. Cleaning with CO2 and air-jet/deionization
3. Spray coating with Cartesian robot
4. Lacquer flow, flash-off
5. IR and UV oven for first drying
6. Vertical oven for final drying
7. Line unloading and quality control

Automotive component production: the materials used in finishing

High-precision machines need to be matched with top-quality materials. Hence Cefla Finishing’s entry into strategic partnerships with the major lacquer and coating suppliers.

Thanks to an in-depth understanding of consumables and their characteristics, solutions provided to customers can be configured to optimise both the consumption and yield of the materials. In automotive component production, that means:

• Lacquers (water-based and solvent-based): resin and pigment-based, available in different finishes and colours
• Primers: used to improve adhesion of the lacquer to the surface of the component
• Anti-rust coatings: to protect components from corrosion
• Lubricant coatings: to reduce friction and wear

Future trends in automotive component finishing

This is the present. But what about the future of automotive component finishing? Well, one of the key trends in the sector is the use of low-bake lacquers, which can be dried at lower temperatures than their traditional counterparts. To be specific, about 80/90 °C as opposed to 140/160 °C.

Specialised producers of automotive components are also increasingly focused on systems that automate the coating process, such as systems with robotic stations that use dry-type lacquer filtration mechanisms.

Market developments aside, one thing is certain: companies operating in this extremely competitive sector must always ensure their customers - car makers - can count on productivity, quality and efficiency.

And that’s where flatbed systems - a Cefla-developed solution for the ultra-efficient finishing of automotive components - come into play.

Advantages of flatbed systems

But how do flatbed systems differ from traditional lines? The latter tend to be the right choice when you need to coat large 3D parts: bumpers are a good example of an item best treated using these lines.

However, when items are smaller (up to 30 cm high), flat lines, or flatbeds, are decidedly more flexible and efficient. The technology is therefore particularly suitable for vehicle interiors, which have numerous components that require a high-quality process.

The flatbed lines implemented by Cefla Finishing include a robotic system with a scanner to detect pieces that involve minimal programming. Each booth can host up to two different robots. This boosts the processing speed or the coating circuit, with users able to select between intelligent or continuous spraying, depending on the shape of the objects.

Flatbed lines can handle different, even mixed, parts on simplified masks: such masks only need to be rectangular with a flat frame and, of course, they need to hold the parts in position. This approach also makes manual cleaning faster and simpler during loading and quality control.

Note also that this is a modular system (also available with cTracker and cLink line supervision software): it can easily be expanded by adding other standard machines without having to make any substantial modifications. Yet another reason, then, why flatbed lines maximise conveyance flexibility: there's no need for step movements as on traditional lines because each machine can act independently.

Adopting a flatbed solution provides tangible, measurable advantages:

• Compact operation, resulting in less consumption and reduced exhaust air flow
• An easier-to-manage process, with consequent labour and energy savings
• Lower cost per coated part

Why choose Cefla Finishing to optimise automotive component production?

The automotive component manufacturing sector is constantly evolving: technology is progressing at a blistering pace, with digitalization paving the way for new, innovative finishing solutions.

Nevertheless, we’re still talking about a complex, delicate process that is crucial to vehicle quality and performance: so nothing can be left to chance. This is why it’s vital to team up with a technological partner with skills that go beyond the technology itself: a partner able to deliver high-performance products, continuous innovation, expert assistance and a commitment to joint research and development. That partner is Cefla Finishing.

If you’d like to see what we can do for your business, and experience the effectiveness of our solutions for yourself, contact us: we’ll put you in touch with one of our experts.

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Today, flatbed coating lines can play a fundamental role for companies in the automotive sector. The thought goes primarily to those players who, in an aim to strengthen their positioning in the sustainable mobility market, focus on manufacturing vehicles mainly made from lightweight and easily recyclable materials. To be precise, we are talking about plastic, particularly for the production of interiors that must be functional, resistant and aesthetically satisfying.

Finishing and decoration processes for plastic components therefore become an integral part of a value chain that aims to combine perceived quality, performance and low environmental impact. And this is exactly where flatbed solutions come into play.

What flatbed coating lines are

Let us start by defining this approach to finishing. A flatbed line, as the name suggests, is based on an architecture that features a flat and stable surface for material processing.

Generally, the solution consists of one or more in-line conveyors where the products are placed to undergo various operations required for their coating. Positioning the parts flat—usually fixed onto support frames—allows uniform treatment across all parts, with higher productivity compared to traditional solutions.

This principle has made flatbed lines essential tools in finishing processes that aim to optimise material handling and coating operations. This facilitates quality control, improves overall production efficiency and reduces waste.

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The benefits of flatbed coating lines in the automotive sector

This is why, in the automotive sector, adopting a flatbed line can offer several advantages over more traditional coating solutions. The main benefits are:

Efficiency and speed.
Flatbed lines are designed for continuous operation, enabling faster processing times. Thanks to their greater width, they can handle more pieces simultaneously, significantly reducing production times compared to traditional methods.

Repeatability and quality.
Automatic flat coating systems guarantee uniform coverage and consistent quality on all parts. This reduces the variability typical of manual coating, leading to superior finishes and fewer defects.

Optimisation of process stages.
Cefla flatbed lines have independent conveyors, allowing different advancement speeds in the various stages of the process. This means that loading, cleaning, coating, flash-off, drying, unloading and quality control times can be adjusted according to the specific requirements of each stage, independently of one another.

Cost control.
Although the initial investment in a flatbed line may be higher, long-term savings are substantial. Reduced labour costs, lower material waste, reduced energy consumption and increased productivity generate an extremely rapid ROI.

Versatility.
Flatbed lines can process a wide range of substrates, sizes and shapes. This flexibility enables manufacturers to work with different types of products without having to modify coating programmes, making it easier to respond to changing market demands.

Improved environmental control.
Modern flatbed systems include features that control overspray and manage VOC emissions more effectively than traditional methods thanks to lower and optimised airflow rates.

Monitoring and data collection functions.
Advanced flatbed systems can be equipped with integrated monitoring and data collection capabilities, allowing manufacturers to assess performance, optimise processes and take data-driven decisions for continuous improvement, as well as enabling traceability by matching process data with the parts produced.

Flatbed lines vs. traditional coating systems

But when is it really advisable to use these solutions?

If vertical spray coating lines are more suitable for handling larger components (such as bumpers), smaller parts—such as those used in car interiors, generally made of plastic—have different requirements.

Flatbed lines, besides ensuring better productivity, deliver better quality because overspray—typically responsible for defects in this type of processing—is removed from below.

In particular, the Cefla Finishing flatbed finishing solution not only offers 20% higher productivity compared to traditional systems but also delivers excellent glossy black (piano black) finishes on plastic components.

Cefla’s approach: integrated lines for a fully automated coating process

There is another element to consider. Today, the needs of entrepreneurs and plant managers receiving orders from the automotive world increasingly move towards complete solutions, including:

• equipment for automatic part cleaning, increasingly using dry ice with no environmental impact
• spraying robots with reduced—or zero—programming requirements
• large ovens and UV lamp systems for in-line drying

The flatbed approach fits perfectly with this philosophy.

At Cefla Finishing, we specialise in designing flexible, complete and turnkey finishing solutions. A Cefla flatbed coating line for piano black interior parts includes the following stages:

• Surface preparation:
  Automatic cleaning with dry ice and deionisation with the Mito oscillating spray coater. 
• First coating application:
  The components pass through a 2D or 3D reading barrier into the iBotic cartesian spraying robot for the application of the basecoat. 
• First drying: 
  the coated components move into the Omnidry vertical oven for 20-30 minutes. 
• Second coating application:
  A new clearcoat layer is applied, again by the iBotic cartesian spraying robot.
• Final drying:
  Passage through the Omnidry oven for 45 minutes at 70°C, and optional double curing using ultraviolet lamps in the UV oven (UV-R M2)to increase surface hardness.

Automation in coating lines: from robots to monitoring software

There are also components that require different processes. How can these be managed automatically and intelligently within a flatbed line? The answer comes from Cartesian robots and, above all, from line software such as cTracker.

This tool monitors the line and automatically regulates coating operations and process parameters, such as the correct temperatures for subsequent drying. In this way, each component can receive the most suitable treatment without slowing down or stopping production.

But this is not the only advantage. Thanks to cTracker, it is also possible to monitor the pieces on the line, record data and analyse productivity. These features allow production changes to be implemented without emptying the line, managing and tracing each part frame from a single point and adjusting all machines according to preset recipes or real-time needs.

In conclusion

In the automotive sector, the needs for innovation and sustainability find a response in flatbed coating lines, which stand out for quality and efficiency in producing plastic components for car interiors.

Adopting integrated flatbed lines is, in short, a strategic choice for companies aiming to position themselves at the forefront of the market, combining superior production performance with impeccable quality results.

Want to switch to a flexible, efficient and premium-quality coating system? Contact us—our experts are at your disposal for a professional consultation.

The expression “production process” contains a key concept related to business management and, more generally, modern economy. It is the set of procedures, activities and skills involved in the processing of raw materials into finished goods and services.

What is a production process?

According to its most exact definition, the production process – or production cycle – is a method by which inputs (raw materials, labour, technology and capital) are turned into outputs, i.e. products and services. There are different production logics: one is based on orders, another one on batches, one is mass-based and another one is continuous; each one is characterised by different phases, going from the initial idea of a product to its design, all the way to actual implementation and delivery of the output package to the end consumer. It follows that understanding how each stage works and incrementally identifying areas for improvement is essential for organisations seeking to optimise business efficiency, reduce costs, and meet customer requests.

Let's see in more detail, before analysing the approaches that can help improve overall management, what the different phases of the production cycle consist of.

Planning and design

The process starts with brainstorming sessions for the creation of new products and services or for the improvement of existing ones. The activity includes market research to focus on consumer needs, feasibility studies and prototype creation.

Procurement

Once the project is finalised, the next step is to purchase the necessary raw materials and components. This phase often involves negotiating with suppliers, assessing quality, and handling logistical challenges.

Production

The next step is the actual production phase. Depending on the nature of each product, there may be different production chain set-ups: the choice of the most suitable one impacts both process efficiency and output quality.

Quality Control

During the production cycle, companies implement quality control measures to ensure that products meet specific standards. Let's review the inspection, testing and regulatory compliance processes.

Packaging

After production, the products must be carefully packaged for distribution. The purpose of packaging is not only to protect goods, but also to play a critical role in marketing and branding.

Distribution

The final phase consists in delivering the finished products to retailers or directly to consumers. This involves managing logistics, inventory and transportation to ensure that products are available wherever and whenever they are needed.

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Production process improvement

The matter is extremely complex - as all those working in the field are well aware of. However, not everyone is aware of the fact that analysing the data generated in each of phases listed above can significantly improve the production process.

A data-centric strategy, especially if implemented within a modular and flexible technological environment, results in greater efficiency, lower costs and improved product quality, enabling organisations to make informed decisions, even in real time, to proactively respond to critical issues, or to anticipate problems before they even occur. Organisations that adopt data analytics systems are also better positioned to adapt to changes and improve production capacity even in times of crisis.

Data analysis, however, is only the first step on the way to smart manufacturing. Today, companies can use simulation models that provide a “digital twin” of new or existing production scenarios by feeding to them data generated by existing processes (we will see an example below). This makes it possible to consider the adoption of different strategies and identify optimal workflows before implementing changes in actual practice.

The same approach can be applied to people management. Data analysis and simulation development help assess employee productivity and performance, identifying areas where staff may need additional training or support, and also improving shift scheduling. The result is twofold: labour costs are reduced and employee satisfaction is increased.

Finally, by evaluating customer preferences and feedback, a data-centric strategy allows companies to adapt their production processes in order to better meet requests and drive product development so as to responds to market trends and fill any gaps.

Optimisation of production processes

When performed correctly, these activities can help plan specifically targeted actions able to streamline costing policies related to labour, materials, and overheads - thereby increasing profitability.

A well-defined manufacturing process includes quality control measures, ensuring that the end product is up to the required standards while reducing waste. Fine-tuning these procedures can also lead to a significant improvement in the available offering.

A clear understanding of the production process allows companies to adapt their lines to changes in consumer demand, technology and market conditions, helping smoother supply chain management, improving inventory management and shortening delivery times.

Finally, optimising the production cycle is an essentially important choice for companies that aim to minimise possible bottlenecks in the supply chain, to cope with periods characterised by a shortage of qualified workforce and to comply with regulatory frameworks, which, given the increasingly stringent requirements in terms of environmental sustainability, may require significant investments.

Tools for production process simulation: cCloner

How do you carry out, in actual practice, a simulation of the industrial production process and use it to make your process evolve to achieve your business objectives? Cefla Finishing has created cCloner, a line simulator with several advanced features designed to improve each phase of the production cycle and respond to specific market needs.

More specifically, the solution:

• shows a realistic 3D configuration of the line layout, delivering an effective, reliable picture based on measurements, 3D imaging and objective data.
• simulates real line operation. In this way, as early as in the design phase, it is possible to prevent critical issues, avoid machine downtime, and obtain more general information.
• highlights actual productivity and helps identify the best line configuration.

The real strength of cCloner lies in its ability to offer a holistic view of the plant make-up and production process functioning: if used systematically, the software helps to configure each section, thus ensuring that the value chain as a whole complies with production requirements.

Companies that adopt a solution like the one designed by Cefla Finishing can therefore develop skills to not only minimise inefficiencies along the line, but also predict the ROI for plant upgrades.

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