Automatic Spray Coating Line for Metal Components
A metal parts manufacturer installed a complete automatic spray coating line with conveyor system, achieving more consistent coating quality and better process control.
Background
A metal components manufacturer producing hardware fittings, steel frames, and aluminum profiles needed to upgrade their coating process. Their existing manual operation involved 8 workers per shift spraying irregularly shaped metal parts with inconsistent results. Edge coverage was particularly problematic, and coating adhesion complaints from customers were increasing. The factory had no process data or traceability, making it impossible to identify root causes of quality issues.
Customer Pain Points
Uneven coating thickness on complex geometries — edges and recesses were especially problematic
Paint waste estimated at approximately 50% due to overspray and manual inconsistency
Frequent customer complaints about coating adhesion and corrosion resistance
No process monitoring or traceability — impossible to investigate quality issues
Production bottleneck at the painting stage limiting overall factory throughput
High VOC emissions with no adequate exhaust treatment
Proposed Solution
We designed and installed a complete automatic spray coating line tailored for metal components. The system included an automatic conveyor, robotic spray stations, pre-treatment, curing, and paint supply control — all integrated into a single production flow. Online film thickness measurement and MES connectivity provided full process traceability.
System Configuration
Automatic overhead conveyor system with part tracking
Pre-treatment zone (degreasing + phosphating + rinsing)
3x painting robots with automatic gun changers
IR + hot air curing oven with temperature profiling
Online film thickness measurement system
Automatic paint supply and color change system
SCADA integration with factory MES for full traceability
Exhaust air treatment system (water wash + activated carbon)
Project Results
Coating quality significantly more consistent across all part geometries
Better process control with real-time monitoring and data logging
Paint waste reduced by approximately 40%
Customer adhesion complaints eliminated after system commissioning
Labor reduced from 8 to 2 operators per shift (loading/unloading and monitoring)
Production capacity approximately doubled
Suitable Applications
Hardware fittings and fasteners
Steel frames and aluminum profiles
Metal brackets and structural components
Any metal parts requiring corrosion protection and decorative finishes
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