Client Overview
Client: Global Manufacturer – Gas Separation and Filtration EMEA
Location: Gateshead, United Kingdom
Industry: Compressed Air and Gas Treatment, Gas Generation, Precision Cooling
Facility Role: The Gateshead site is a key manufacturing hub within the EMEA region, focused on delivering high-quality, innovative products to support critical process applications worldwide.
Project Summary
In alignment with its commitment to operational excellence and advanced manufacturing, the client commissioned the installation of a new, turnkey powder coating plant at its Gateshead facility. The objective was to upgrade the finishing process to support growing global demand, improve coating consistency, and reduce environmental impact—while maintaining flexibility for both manual and automated production.
In partnershio with Surface Prep UK – We delivered a complete, integrated powder coating system featuring Gema coating technology, Caldan power and free conveyor automation, and a robust 4-stage pre-treatment line—designed to handle a diverse product range while ensuring maximum coating efficiency and repeatability.
Objectives
The project was designed to meet the following key goals:
- Improve coating consistency and surface finish quality
- Enable both manual and automated application modes to suit complex and standard parts
- Integrate a Gema powder application system for world-class precision
- Introduce a Caldn power and free conveyor system for flexible product handling and process control
- Enhance throughput and reduce overall processing time
- Comply with environmental standards through efficient design and waste reduction
Delivered Solution
The solution was designed for flexibility, energy efficiency, and production scalability, combining high-performance equipment with intuitive controls.
System Components
4-Stage Pre-Treatment Plant
- Spray system designed for surface preparation with four key stages: degreasing, rinsing, conditioning, and passivation.
- Optimized for corrosion protection and coating adhesion.
- Gas-fired dry-off oven with uniform airflow distribution.
- Ensures moisture is removed prior to powder application for a clean, dry surface.
Dual-Mode Powder Application Booth
- Integrated setup for both manual powder coating and automated powder coating.
- Manual booths for complex or low-volume parts requiring human flexibility.
- Automated booth powered by Gema powder coating technology:
- Multi-axis application
- Precise film build control
- Fast color change and minimal overspray waste
- Uniform coverage across varied geometries
Caldan Power and Free Conveyor System
- High-precision power and free overhead conveyor system.
- Supports accumulation zones, intelligent routing, and adaptive line speed for efficient workflow management.
- Enables independent control of different workpiece carriers for optimized loading and unloading.
Final Cure Oven
- Gas-fired curing oven with tightly controlled temperature zones.
- Ensures durable and consistent finish that meets international quality standards.
Implementation Process
Design & Planning
Conducted a full site survey and operational analysis with the client’s team. Developed a tailored layout incorporating new powder coating operations into existing production flow. Modeled conveyor paths and booth locations for optimal material movement and accessibility.
Fabrication & Installation
All equipment pre-fabricated and modularized for efficient on-site installation. Safety and compliance standards observed throughout the mechanical and electrical installation phases.
Commissioning & Handover
System tested under full load conditions. Calibration of ovens, conveyor timing, and powder application equipment. Operator training provided on manual and automated systems, with full documentation.
Results & Outcomes
| Benefit | Description |
|---|---|
| Production Flexibility | Operators can switch between manual and automated modes depending on part complexity or batch size. |
| Improved Quality | Gema system delivers uniform, high-quality finishes with repeatability across product lines. |
| Increased Efficiency | Power and free conveyor system reduces downtime and manual handling while improving throughput. |
| Reduced Waste | Powder recovery system and precision application reduce material consumption and overspray. |
| Consistent Curing | Final cure oven ensures optimal coating performance and long-term durability. |
Client Feedback
Conclusion
The successful delivery of a complete powder coating system—featuring a 4-stage wash, Gema technology, Cald’n power and free conveyor, and dual application modes—has empowered the Gateshead facility to scale production, improve product quality, and support evolving customer demands.
This project showcases how tailored, high-performance finishing solutions can support world-class manufacturing operations.
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