2024: a year of events with Cefla Finishing

Certain products are still coated manually because of their inconvenient shapes or because they won’t fit easily onto a standard line. Or simply because they have always been coated manually, so the manufacturer never thinks to search for an alternative solution.

That’s why we are proactive when faced by a request to increase productivity, limit the amount of handling operations made by the operator and improve coating consistency. Our solutions especially through automation as the logical evolution to manual spray coating.

Table legs, stairs, unassembled chairs and loudspeakers

Some products are sprayed manually, moved manually to drying booths and spend more time than necessary in production before reaching the market. Not only is time an issue, but also the physical effort needed to sustain the manual process.

Automation provides an answer by speeding up the process, ensuring quality is consistent and allowing qualified staff to dedicate time to more important tasks.

An overhead line built to handle such pieces can deal with several units at a time, 10 or 20 fixed to a transporting bar. A reciprocating overhead spray coater fitted with a whirling cup device for electrostatic atomisation ensures excellent coating quality, above all consistent, piece after piece. This reduces handling operations and maximises productivity. Automatic rotation of the pieces speeds up the coating stage, optimised by the enveloping effect of the atomised spray, which also significantly reduces lacquer consumption and saves related costs.

Pieces will then be transferred automatically to a drying oven using controlled hot air ventilation for the precise time needed to complete the surface enhancement process.

Each product deserves a personalised approach

Not every product is the same. Our approach will examine the variables in the product (shape, weight, substrate) and take into consideration your targets (budget, productivity, quality). The resulting line concept, moving you from a manual process to automation, will also be designed to ensure maximum sustainability, based on standard technologies and customised to your specific needs.

Contact us and discuss your needs with a finishing expert.

Suspended ceiling tiles: finishing technologies

In the construction industry, suspended ceiling tiles - known also as drop ceilings - are a common feature for residential or commercial buildings. They are made up of a grid framework and a series of tiles made of rock wool or similar composite material.

Types of ceiling tiles

Suspended ceiling tiles can be simple in shape, square or rectangular, with regular edges and a consistent thickness across the extent of the panel. These are commonly referred to as lay-in tiles and fit into the grid, flush with the supporting structure.

The second most common tile, often called a tegular tile, has what is called a revealed edge, so that when placed on the supporting grid, the panel protrudes downwards creating a pattern made up of several tiles with gaps between one tile and the adjacent tile.

Surface and edge finishing according to tile type

Coating of the visible flat tile surface is done on any spray coating machine, whereas the edge is processed using vacuum coating. Our integrated solution enables manufacturers of the ceiling tiles to process the edges in a fast cycle.

When dealing with tegular type profiles, our technological solutions – such as Talent, the patented vacuum system for the sealing of edges - enable you to apply different paint grammage with the same vacuum application head to different sections of the edge. This means you can use more coating on the exposed edge and less coating on the unexposed edge, saving money on the sealing substance where it is less necessary.

Furthermore, there is no risk of overspray on the panel surface, drying using infrared lamps is a rapid step in this single-pass process, and colour changes, if needed, are fast.

If you are interested in examining our solutions for drop ceilings, please contact us for more details.

The finishing sector is undergoing a radical transformation. Thanks to automation and digital technologies, the Cartesian robot is becoming increasingly central to industrial painting processes and, in particular, spray coating.

These systems not only improve the precision and uniformity of the paint, but also help companies reduce energy consumption, increasing the efficiency of production lines. In this article, we will explore how Cartesian robots can bring advantages in terms of energy savings in spraying and energy recovery in painting.

What is a Cartesian robot?

A Cartesian robot (also called a linear or gantry robot) is a robotic system that moves along three orthogonal axes: X, Y and Z. This allows the robot to move in a linear and precise way in three-dimensional space. Its structure is composed of a frame that supports a mobile platform. This platform can move along the axes, allowing the robot to perform tasks such as picking, placing or assembling components with great precision.

Cartesian robots are easy to program and highly repeatable, which makes them ideal for industrial applications such as manufacturing, packaging, material handling and painting. In the latter application, the robots minimise overspray by applying paint only where it is needed. This not only reduces material waste but also allows for energy savings.

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How does a Cartesian robot work?

The Cartesian robot moves along the three axes thanks to motors that drive the platform precisely. The integrated control system guides the stepper or servo motors to perform movements accurately. This makes the robot ideal for pick-and-place and painting operations.

In an industrial context, the Cartesian robot can be programmed to pick components from a conveyor and position them with precision. Furthermore, some robots like iBotic are equipped with self-programming functions, which increases efficiency and reduces errors.

The advantages offered by a Cartesian robot

Cartesian robots offer many advantages. Here are the main ones:

• Superior precision: The precise movements lead to high-quality finishes that are difficult to achieve with manual methods.
• Increased operational efficiency: By automating repetitive tasks, downtime is reduced and efficiency is improved.
• Sustainability: Cartesian robots reduce the carbon footprint thanks to energy savings and the reduction of waste and volatile compounds in the air.

Ease of integration: These robots adapt easily to existing processes

Energy saving in spraying

One of the main advantages of Cartesian robots in painting is the reduction of waste. Thanks to precise control of the spray pattern and application distance, the robots limit overspray and ensure that paint is deposited only where needed.

This leads to a reduction in material consumption and energy savings by limiting additional touch-ups. Furthermore, the use of advanced software allows for the optimisation of paint and solvent mixing, adapting them to temperature and humidity conditions. This ensures optimal paint application, further reducing consumption.

Powerback systems: energy recovery in painting

Another great advantage of Cartesian robots is energy recovery through powerback technology. During the process, a portion of the energy that would normally be lost, such as during deceleration, is stored and then made available to other systems and therefore reused.

This improvement in energy efficiency significantly reduces operating costs. Powerback systems use sensors and algorithms to monitor energy consumption in real time, capturing excess energy to reuse it in other phases of the production process. This not only lowers costs but also contributes to more sustainable production.

The new iBotic: efficiency and reduced consumption

Cefla Finishing has developed iBotic, a high-performance Cartesian robot that has revolutionised the spray-painting sector. Thanks to an updated user interface and an integrated energy recovery system, iBotic is able to optimise efficiency and reduce consumption.

One of the most interesting new features is Timeskip, a device that allows for colour changes without interrupting production. One arm goes into stand-by for cleaning, while the other continues to paint, recovering up to 90 minutes of production time per shift!

A practical demonstration of this technology? Discover how the company Pianca managed to reduce production costs and maintain the same standards of quality, customisation and impeccable service with Timeskip: discover the Case Study.

✅New functions for greater productivity

The new functions of iBotic have been developed based on customer needs. The innovations include:

• Spray angle adjustment: Automatically adapts the paint application to different shapes.
• Quick gun cleaning: Optimises colour changes and reduces downtime.
• Simplified maintenance: The water circulation system reduces areas of stagnation, improving cleaning.

These functions increase productivity and efficiency, making the robot ideal for meeting the growing demand for customised production.

✅New user interface

The iBotic user interface has been designed to be simple and intuitive. Operators can easily manage and program the robot, with rapid learning and without the need for complex training. Furthermore, iBotic integrates seamlessly with ERP systems for optimal production management.

✅Energy recovery system: reduction of running costs

Of course, a powerback system has also been implemented on the new iBotic, which allows for energy savings of 15-20%, reducing operating costs and increasing overall sustainability.

Discover more on iBotic in this webinar.

In summary, the Cartesian robot represents an innovative solution for the painting sector, offering advantages in terms of energy savings, efficiency and superior performance. With the adoption of advanced technologies such as energy recovery, manufacturers can not only reduce costs but also improve the sustainability of their operations.

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Innovation in coating automation now offers companies a breakthrough in terms of efficiency, quality and flexibility. Thanks to advanced systems, it is possible to manage even three-dimensional or irregular objects in a standardised and repeatable way, reducing labour costs. In this article, discover how an automated coating line can transform production by adding value, safety and control over the entire process.

What is an automated coating line?

Before we get into the specifics and discover the advantages of implementing an automated coating line, let's define the type of solution we are talking about.

An automated coating line usually refers to a fully integrated system designed to perform coating operations with minimal human intervention. Unlike traditional manual spray-painting processes, an automated coating system incorporates sophisticated handling, spraying and drying mechanisms to optimise the entire process. These architectures are often equipped with conveyor or robotic transfer mechanisms, which move parts seamlessly through the different stages, ensuring uniform coverage even on complex or irregularly shaped products.

The main advantage of an automated spray coating line lies in its ability to replace manual operations with precise and repeatable actions. Automated coating systems use programmable controllers to regulate spray parameters, movement trajectories and drying conditions.

Key components of a spray coating line

The latest generation of spray coating solutions are true technological ecosystems: a complete line includes several integrated elements that work in a complementary and harmonious way. Reviewing the key components of automated coating systems, we can certainly mention:

• Automated spray booths: enclosed environments with controlled airflow and ventilation, designed to optimise spraying conditions and ensure uniform coating application.
• Reciprocators and robotic spray arms: programmable mechanical devices to move spray guns precisely along complex paths, essential for intricate geometries.
• Automatic spray guns: high-precision nozzles, adjustable for various coating materials and product shapes.
• UV curing systems and drying units: for rapid polymerisation of coatings and efficient curing, reducing cycle times.
• Conveyor or handling systems: automated devices for transferring parts through the various stages of the line, maintaining flow and precision.

Each component can be customised according to the application's requirements, making automated spray coating systems adaptable to different sectors and product complexities.

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Advantages of automated coating systems

Thanks to the synergy of these machines, automated coating systems offer numerous advantages. We are essentially talking about advances that have a direct and measurable impact on product quality and operational efficiency, which ultimately generate substantial economic benefits.

In particular, thanks to an advanced spray line, it is possible to achieve:

• Superior finish: automated painting = uniform, defect-free layers even on irregular surfaces; less reworking and retouching.
• Accelerated processing times: automated systems complete cycles more quickly than manual methods; greater productivity.
• Material efficiency: precise control of parameters, less overspray and less waste, lower material cost.
• Uniform application: constant thickness on every piece, even on complex shapes, thanks to programming.
• Minimal labour for handling: automatic positioning allows operators to focus on strategic stages of the process.
• Greater safety: workers are less exposed to hazardous fumes and overspray, creating a safer environment.
• Flexibility and customisation: suitable for numerous substrates, coatings, geometries and sectors (automotive, aerospace, consumer electronics).

These are the advantages that, in general, can be obtained by integrating an automated coating line. But it is when the solution is customised that the true potential is unleashed.

Ground-level lines facilitate the coating process

Cefla Finishing builds its offering on modularity and customisation. Floor-fixed spray lines are custom-designed and assembled for every need. This flexibility allows us to specifically follow the customer's product, developing automated lines based on process objectives.

When customising the line, Cefla integrates the best spray coating technologies, such as the iGiotto robot or, on request, machinery developed with third parties. A 3D scanner reads the shape of complex products, sets the spray trajectories and repeats them over the entire batch. A concrete example: an automated line in an automotive components factory achieves high quality on complex body panels and reduces cycle times and waste. In the absence of automation, the operator has to move around the piece, position it, paint it by hand, and transfer it to be dried. The automatic line, however, allows the product to move and rotate, with the robot painting it seamlessly, right through to the drying stage.

Customisation and integration for various industrial sectors

The automotive sector is just one of the fields where automated coating systems are a winning use case. Automatic coating lines are extremely versatile and adaptable.

• In the aerospace sector, automated systems coat complex components with tight weight and performance tolerances.
• Consumer goods manufacturers use flexible solutions to handle many types of products, even small or complex ones.
• In industry, these systems are used to coat large mechanical components with irregular geometries.

Configurable options (multi-axis robotic arms, adjustable parameters, modular stations) help every manufacturer to optimise results on any material and coating. All this versatility stems from the modular approach and seamless integration into existing production lines, allowing for optimised workflows.

Some examples of our floor-fixed coating solutions

Given the multitude of cases in which a customised line can be successfully implemented, Cefla Finishing offers pre-configured solutions for many real needs already found on the market. The following can be processed on our automated coating lines:

• Motorcycle helmets
• Sofa legs
• Plastic flower pots
• Rifle stocks
• Pianos and grand pianos
• Shoe trees
• Coffins and caskets
• Sidings
• and much more.

Rely on our experience to find a tailor-made solution

Cefla Finishing has years of experience in creating automated coating lines, both overhead and floor-fixed. Every solution is developed based on the customer's specific requests: every product is different; therefore, coating and drying techniques change. We do not offer standard solutions, but rather tailor-made projects created thanks to proven experience and international technological know-how.

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Door/window manufacturers and sub-contractors who finish intermediate wooden or PVC products are always looking for new coating solutions: integrated machines and lines that not only ensure the best possible output but also allow them to create products that genuinely meet each customer’s specific needs. Solutions such as these deliver true innovation to the industrial coating sector.

Innovation in industrial coating

Today’s challenge consists of simplifying the industrial coating process with groundbreaking solutions, taking into consideration several parameters:

• production volumes
• demand for flexibility
• type of substrate
• specific requisites of final products.

At the same time, it’s crucial to act on four key aspects:

• finishing process control
• lacquer consumption control
• coating quality/uniformity control
• awareness and control of production efficiency and production potential.

What is an anthropomorphic coating robot and what are its advantages?

Let's dive deeper and see what solutions based on anthropomorphic robots consist of:

Minimising manual tasks by deploying machines capable of reproducing workers’ movements is the fastest way to obtain consistent quality regardless of the shift, the worker or the time of day the work is done. Furthermore, the greater the degree of automation, the easier it is to maintain control of the entire process.

Those who use a line of anthropomorphic robots for coating can:

• coat large, geometrically challenging pieces
• monitor consumption
• assess production efficiency
• take action to adapt to market demand.

Easy to program thanks to proprietary software developed by Cefla Finishing, anthropomorphic coating robots installed on overhead lines are extremely user-friendly, require no specific skills, and have minimal maintenance requirements.

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Overhead coating lines: flexibility and productivity

When it comes to finishing complex three-dimensional objects such as windows and doors, unassembled chairs or even musical instruments, using anthropomorphic robots on overhead lines is essential to achieving high-quality coating results that deliver smooth, even surfaces.

But that’s not all. Combining automated systems with intelligent loading and unloading mechanisms minimises the machine downtime associated with colour changeovers.

Anyone who manages orders with a high level of product customisation knows that flexibility is an essential component of productivity. For this reason, only a custom-designed range of coating solutions can successfully adapt to the specific nature of the production plant and the type of companies it serves.

Cefla Finishing is well aware of this: that’s why it offers customers a range that focuses on integration and compatibility.

iGiotto: an integrated coating system

iGiotto is, above all, a spray coating solution that can be fully integrated with special software, allowing the manufacturer to control every aspect of the spraying process. Able to work with water- or solvent-based lacquers, it features an anthropomorphic spray robot that works at programmable speeds while maintaining a stable gap between spray gun and workpiece. In essence, this set-up ensures optimised consumption of the lacquer and its uniform application.

Specially developed in-house software lets you set all the process parameters and start production, with minimal operator intervention as all the worker has to do is load the pieces onto the vertical line. Note also that iGiotto sprays the pieces as they’re being conveyed, increasing overall line efficiency.

When iGiotto is integrated into a complete line, the pieces pass through a drying tunnel and are then collected and unloaded, either in batches or individually.

iFlow: wood impregnating solutions

iFlow is, instead, a spray-type wood impregnation machine. Developed using ‘smart design’ principles that streamline cleaning and general maintenance tasks, iFlow is the perfect addition to lines that seek to maximise production efficiency. This coating solution is, in fact, expandable: it allows for the inclusion of a second unit to manage different types of finishes and colours within the same time frame.

Automatic loading and unloading: integration with overhead lines

A high-efficiency overhead line can only be considered complete if it features an integrated product handling system.

To minimise manual tasks - and allow operators to focus on supervising the line - Cefla Finishing has developed iLoad, a cutting-edge solution for automatic loading/unloading of overhead conveyors.

Sustainable coating: an achievable goal

Bringing all the features of these machines together on a single coating solution doesn’t just boost plant productivity: it also significantly improves the sustainability of the entire value chain.

Less lacquer consumption - which leads to reduced use of wash water, less refuse, fewer filters and less maintenance - leads to a reduction in waste and lessens the environmental impact of operations.

Why Cefla Finishing? The advantage of being global

A global presence, combined with in-depth experience gained in highly localised situations, allows Cefla Finishing to provide unique solutions for unique needs.

Just think of how coating processes vary according to the type of wood used (conifers, broadleaved trees, exotic woods, etc.). What’s more, finishing processes are also affected by ambient conditions. For example, coating types and processes in cold countries (e.g. Scandinavian nations) will differ considerably from those used in warmer, sunnier countries such as those in the Mediterranean area. Each geographical setting has its own peculiarities, and local companies need to take them into account, as must their suppliers.

Cefla Finishing is an international player that has built its reputation by intercepting different needs on different markets: a factor that, today, makes it an ultra-reliable partner for small, medium and large companies alike.

How to choose the right solution for your company

Established to meet customers’ individual needs, the Cefla Finishing Lab is a true technological hub that aims to pool experiences, business models and new technological opportunities.

Visitors to the Cefla Finishing Lab can see more than a hundred machines in operation, create and test entire processes on-site and pinpoint the best settings to maximise production line performance.

In other words, visiting our Lab means discovering the coating solutions that best suit your specific requirements and calculating the ROI needed to make finishing lines increasingly efficient.

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