Edge coating is relatively simple when the geometries of the workpieces never change: but when batches of products largely different in terms of edge shape and size have to be processed, things become definitely more complicated. Whenever the type of product changes, the machine needs to be stopped to reset the application head.
How many times in a day can this happen? How much machine downtime is generated, and for how long? Is there a way to make line setup changes more efficient and speed up production?
These are the questions asked by finishing plant managers: so far, however, the answers have been less than encouraging. Removing application heads and realigning components according to the shape or size of the edge of the next product to be processed is a complex, time-consuming operation, which must be carried out by skilled workers.
However, thanks to the application of new technologies to the edge coating process, finishing lines can now achieve a degree of flexibility that was unthinkable up until just a few years ago.
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Technological innovations in edge coating
Automated systems are effectively revolutionising edge coating techniques, minimising human intervention and maximising process efficiency. Robotic arms guided by sophisticated algorithms can apply lacquer to edges precisely, reducing overspray (and the resulting material waste) and adapting to different component shapes and sizes - which leads to more flexible production lines.
New spraying solutions such as High Volume Low Pressure systems and others based on electrostatics have significantly improved the application of edge coatings, allowing for more homogeneous finishes and reducing environmental impact.
Integrating smart sensors into edge-coating processes means enabling performance monitoring to ensure real-time feedback: sensors can detect coat thickness, surface temperature and environmental conditions, allowing for automatic adjustments in order to maintain optimal application standards.
Finally, digital inkjet printing technologies should also be mentioned as emerging valid alternatives for specific applications. Compared to edge coating, this process allows for high-resolution images and patterns to be printed, enabling high levels of customisation without any significant changes to the line setup.
FOR MORE INFORMATION:
Coating of panels and edges: digital printing offers a new alternative
Edge&Go: a revolution in edge coating productivity
It is by combining the characteristics of some of these technologies that Cefla Finishing has developed Edge&Go, a simply revolutionary, patented system for edge coating. The device combines flexibility and user friendliness, automatically adapting to the different edges that reach the finishing line and allowing, where necessary, quick changing of the workpieces.
Integrated in the Smartedge system - the complete solution from Cefla Finishing for coating and sanding flat and raised panel edges - Edge&Go can boost the productivity of any type of line beyond all expectations, maintaining high quality standards for all edge types.
Advantages of automated coating over manual coating
One of the most significant advantages of using automated coating systems lies in the line's ability to ensure quality consistency. Unlike manual processes, which can by influenced by human factors including operator skills and levels of tiredness, robotic systems will follow predefined paths and parameters precisely. This ensures that each product is processed consistently - resulting in higher-quality finishes and fewer defects.
Obviously, robotic processes can be carried out continuously and at higher speeds than human-controlled processes, resulting in increased productivity and improved workplace safety.
Automatic systems are also designed to optimise the use of materials, thus reducing waste and (economic and environmental) costs related to consumables. Advanced edge coating techniques, such as electrostatic spraying, result in more efficient lacquer application, minimising overspray and the need for touch-ups.
Last but definitely not least, the flexibility and scalability ensured by robotic finishing and coating systems allow production lines to be easily modified with minimal downtime whenever production processes need to be adapted. This also means being able to quickly scale up or down production capacity based on demand without excessive costs.
Customised solutions for different types of edges
Edge&Go is just one of the innovative solutions that Cefla Finishing has created to help companies improve their edge coating processes. These components' ability to adapt to different production needs is ensured not only by the flexibility typical of systems natively designed to handle different types of panel, but above all by Cefla's industry-specific expertise.
Tuning in to customers, understanding their needs, an in-depth knowledge of the materials and tools used: these are the assets underlying Cefla Finishing's consultancy, which results in the supply of tailor-made solutions, with customised functions, capable of supporting streamlined processes, essential to successfully adapt to new, competitive scenarios. Come and test Edge&Go in our LAB.
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