Overview
To meet growing production demands and maintain high-quality surface finishing standards, our client Surface Pre partnered with us to design, install, and commission a state-of-the-art powder coating plant. This facility was engineered with flexibility, energy efficiency, and throughput optimization in mind, leveraging advanced automation, premium coating technologies, and robust control systems.
The result: a future-ready plant with dual-line functionality, seamless material handling, and industry-leading coating capabilities.
System Components and Key Features
Power & Free Automated Overhead Conveyor System
At the core of the system is a power and free overhead conveyor—a high-capacity material handling solution that offers unmatched flexibility. The conveyor network efficiently feeds both the automatic powder coating line and the manual touch-up line, allowing simultaneous operation without bottlenecks or production halts.
- Dual-lane operation: Supports routing to auto or manual lines based on part geometry or coating requirements.
- Precision tracking: Part identification and tracking ensure accurate routing and process control.
- Load/offload accumulation zones: Strategically placed to buffer parts and optimize operator efficiency.
Automatic Powder Coating Plant with Cyclone Recovery System
The main coating line features a fully enclosed automatic powder coating booth, equipped with a cyclone recovery system and after-filter for superior powder utilization and environmental performance.
- Efficient color change design minimizes downtime during batch transitions.
- Cyclone recovery enables up to 98% powder reclaim.
- After-filter unit ensures clean air discharge, exceeding environmental compliance standards.
Gema 6-Gun Automatic Reciprocator System
The heart of the automatic application process is a Gema 6-gun reciprocating system, delivering consistent and high-quality finishes across various product geometries.
- Uniform application with advanced electrostatic controls and adjustable spray patterns.
- Reciprocators synchronized with part movement for optimal coverage.
- Compatible with a wide range of powder formulations and colors.
Two On-Line ISS Manual Cartridge Powder Booths
For manual coating needs and complex geometries, the plant includes two ISS cartridge powder booths, integrated into the main conveyor loop for in-line manual coating without process disruption.
- Fast color change technology with easy-clean design.
- Integrated extraction for operator safety and booth cleanliness.
- Ideal for rework, low-volume runs, or parts requiring special attention.
Two On-Line ISS Manual Cartridge Powder Booths
For manual coating needs and complex geometries, the plant includes two ISS cartridge powder booths, integrated into the main conveyor loop for in-line manual coating without process disruption.
- Fast color change technology with easy-clean design.
- Integrated extraction for operator safety and booth cleanliness.
- Ideal for rework, low-volume runs, or parts requiring special attention.
Sophisticated Control System with Siemens PLC
At the heart of the plant’s automation is a Siemens PLC-based control system, paired with a 21-inch full-graphics HMI interface. This system provides complete control and real-time monitoring of the entire coating process.
- Intuitive HMI dashboard for operator-friendly control and diagnostics.
- Recipe management for quick production changeovers.
Data logging and reporting for process tracking, QA, and maintenance planning.
Results & Benefits
- Increased production throughput with reduced manual handling and downtime.
- Consistent, high-quality finishes across a variety of product types.
- Significant powder savings through reclaim and efficient spray technology.
- Improved operator safety and ergonomics.
- Full process traceability and predictive maintenance via the advanced control system.
Conclusion
This powder coating plant represents a benchmark in advanced finishing solutions. Through the seamless integration of automated conveyors, state-of-the-art powder application equipment, and intelligent control systems, we have delivered a facility that not only meets today’s production needs but is also scalable for future demands.
Whether you’re aiming to reduce environmental impact, improve finish quality, or increase operational efficiency, this installation stands as a testament to what’s possible with the right engineering partner.
Looking to Upgrade or Build Your Own System?
Contact us today to learn how we can customize a powder coating solution
to suit your unique production needs.
Explore More
