3 reasons to move from a manual to an automated spray coating process
This is a question most often asked by smaller companies employing no more than a dozen staff. As the market becomes more demanding in terms of lead times and quality standards, manual spray coating techniques have a number of drawbacks.
You may not realise, but transfer efficiency is no higher than 25% and often the pieces need to be re-sprayed when the quality achieved is not in line with the customer’s expectations. Such issues are putting pressure on small outfits using manual labour and the pressure is felt not only by the owners, but also by the operators themselves.
Reworking products also takes time, not to mention the cost of extra lacquer and labour, and it leads to inevitably longer delivery times, something your customers will not appreciate. Reworks can be avoided.
Switching from manual to automated spray coating may seem like a step into the unknown for some companies, but the return on investment will soon be felt. An initial investment with some reorganisation of floorspace will be necessary. One or two operators will need to learn a few basics before being able to program the equipment, but once this is done, they will only need to oversee the process, load and unload workpieces and keep to schedule. What you will notice is that coating quality consistency will no longer depend on which operator is spraying, how much coffee he had or whether he is spraying well at 9 a.m. or spraying as best he can at 5 p.m. – it makes a difference!
How will an automatic spray coating machine improve all this?
- Firstly, you will obtain the same quality without any variations, so once it is satisfactory, you just need to push a button and let the machine accomplish the rest.
- Secondly, you will save on lacquer because transfer efficiency will increase significantly, in some instances reaching more than twice as much compared to manual spray coating.
- Thirdly, your production efficiency will increase and consequently delivery times will be reduced, so you can accept more business and maybe extend your customer base.
- Fourthly, labour costs can be cut because you only need one operator to manage the programming and supervision of the equipment, as well as loading and unloading the pieces.
So what are the 3 reasons?
Simple, we have created several spray coating solutions, but many of these are sophisticated machines handling complex geometries, processing on flatbed or overhead lines and using special anthropomorphic robots.
But there are 3 solutions which represent a perfect first step into the world of automated spray coating:
Before you make a choice, there are a few things to consider. Base your decision on the goals you aim to achieve, not on your current capacity. Consider your need to make frequent colour changes; in this case you should opt for Prima, an excellent solution when dealing with frequent colour changes or several small batches. Mito can be fitted with one central or two lateral arms, and is good for small to medium outputs. Easy will be suitable for handling medium to large volumes and can be fitted with a number of optional features.
If you are keen to learn more about moving from manual to automated spray coating, our experts will be happy to personalise the solution according to your real needs.
So if you are ready to explore the new potential awaiting you and your business, contact us for more details.
