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.

LOOKING FOR THE IDEAL SOLUTION FOR YOUR COATING LINE?

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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When using 100% UV lacquers, there is absolutely no way to avoid the stage where crosslinking takes place under UV lamps. And that process depends on photoinitiators contained within the lacquer. These photoinitiators directly influence the cost of the lacquer and their cost and availability fluctuates heavily. They are also partly the cause for undesired yellowing effects and are harmful to the environment. One way of minimising these negative aspects would be to minimise a company’s need to use lacquers containing current quantities of photoinitiators. UV-I oven does exactly that.

An inert atmosphere reduces the need for photoinitiators

• reducing the cost of the lacquer
• reducing the harmful environmental aspects
• reducing the yellowing effect
• reducing a company’s dependence on external factors which influence costs

UV-I oven: better crosslinking, improved coating performance

Not only does the inert atmosphere reduce the negative aspects, it also increases the degree of crosslinking achieved which leads to better coating film performance and stain resistance. Fewer photoinitiators, a factor made possible by minimising the inhibitory effect of oxygen, makes it possible to crosslink even thinner layers than today. This allows companies to choose between using less lacquer or boosting production speeds by maintaining the same amount of photoinitiators inside an inert curing oven, even if the latter option will not benefit the environment.

Under normal circumstances, crosslinking is always superior where the lacquer is in contact with the panel surface. This is because the oxygen in a standard UV oven will counteract crosslinking on the outer layer.  The thinner the lacquer layer, the greater the risks are of poor crosslinking performance throughout the coating thickness.

UV-I oven favours excellent crosslinking on the outer layer, so even thinly coated panels will be perfectly cured.

Production costs also drop

Alongside the reduced lacquer costs, fewer UV lamps are needed for the curing process. This leads to lower energy requirements and costs. And as crosslinking takes less time in an inert atmosphere, production volumes can be increased and made more cost-efficient.

Discover our selection of ovens and drying solutions.

What is UV curing and what advantages does it provide in the delicate drying phases - essentially important to complete product finishing processes? The first consideration to make is that - regardless of the type of lacquer to be applied and the items to be processed (flat or raised panels, or panel edges) - new curing solutions keep appearing on the market, based on fast-evolving innovative technologies.

Understanding which winning combination could help you build the most efficient curing system to suit your needs - based on the substrates to be treated, your type of process and your production volumes - is essential in order to maximise the advantages offered by the new machines.

LED technologies

An analysis of the current curing scenario can only begin by mentioning LED technologies, which are playing an increasingly leading role in UV curing processes. After their introduction, LEDs have rapidly gained ground in several industrial applications, replacing traditional systems based on gallium or mercury lamps.

Some industry players are particularly interested in the opportunities offered by UV LED lamps. However, the general market has not yet fully grasped the potential benefits of LED technologies. These can offer significant advantages, particularly to companies active in specific areas:

1. Panel finishing companies willing to invest in a new integrated finishing line, or to replace old UV ovens equipped with mercury or gallium lamps.
2. Edge coating businesses interested in adopting LED UV technologies.
3. Companies that use industrial digital printers, a segment in which LED technologies are already widely used for the pinning and final drying phases.

LED UV Curing: main advantages

Obviously, each one of the three applications mentioned above has specific requirements, but it is still possible to identify a number of common benefits:

• improved sustainability
• operating costs reduced to a fraction
• safety and flexibility
• control over process stability
• long lamp life and minimal maintenance requirements

Differences between traditional UV and LED curing

Going into more detail, there are five factors underlying the clear superiority of LED curing compared to curing with traditional lamps. Let's review them:

1. Ultraviolet light source

In traditional UV curing, the lamps require a warm-up period and have a relatively short lifespan, requiring more frequent replacements.

LED UV curing uses light-emitting diodes specifically designed to emit UV light, typically in the UV-A range. LEDs turn on and off instantly, providing instant curing without needing any warm-up time. They also last longer and are much less energy-intensive.

2. Energy efficiency and environmental impact

Traditional UV curing is not only more energy-intensive but also requires the disposal of hazardous materials, resulting in environmental risks. Additionally, traditional lamps will expose the coated films (and consequently, the substrates) to considerable heating.

LED systems are more energy efficient, as they convert a greater amount of electrical energy into usable UV light and will produce less heat. This level of efficiency reduces energy costs and improves sustainability by minimising the carbon footprint associated with curing processes.

3. Material compatibility

In traditional UV curing, the broader light spectrum emitted by mercury vapour lamps can cure a wide variety of product formulations, including some that might not work well with narrower UV wavelengths. However, this versatility comes at the cost of increased heating, which can limit the types of substrates that can be used.

While if LED curing is compatible with a limited range of materials designed to respond to specific wavelengths, advances in product formulations are continually expanding the range of resins and coatings that can be cured.

4. Cost management

The initial investment needed for mercury vapour UV curing systems is lower. However, this cost tends to increase due to maintenance and lamp replacement requirements and increased energy consumption.

LED systems tend to have a higher initial cost, but long-term energy savings, low maintenance needs and longer life often make them a more economical option over time.

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Common issues in UV curing (and solutions provided by LED technology)

The differences listed here above lead to very different outcomes when it comes to the effectiveness and efficiency of production lines. First of all, it is impossible to achieve the required curing process stability with mercury lamps without having to frequently measure their intensity and constantly monitor their operation. This often leads to downtime and loss of production capacity. Additionally, a mercury lamp has a life span of 1500/2000 hours, while an LED lamp lasts approximately 30,000 hours without suffering any significant UV intensity losses.

Panel overheating caused by traditional UV lamps should also be considered. MDF panels and resinous woods are significantly affected, as they can exude resin at high temperatures. UV LED lamps, by contrast, are much cooler and have no adverse effects on these substrates.

And what about environmental sustainability? Disposing of mercury lamps requires a lot of red tape in addition to causing ecological concerns (the RoHS directive prohibits mercury lamps for home use, and this rule could easily be extended, in the future, to industrial applications), and UV LED lamps are so much easier to handle in terms of separate waste collection.

As mentioned, standard UV lamps are energy-intensive (which also increases production costs and makes setting up lines difficult wherever the energy supply is insufficient). UV LED lamps' consumption is between 50 and 60% lower than traditional systems based on mercury lamps.

As we mentioned before, cooling systems are required for mercury lamps and they release ozone, which is conveyed out of the facility via an air-cooling system. All this has economic and environmental costs, especially for large production sites, which could partially be avoided with UV LED technology.

UV LED Curing: a modern and sustainable technology

The aspect that ultimately tips the balance in favour of UV LED technology is technological innovation. A UV LED curing system is managed electronically, which means that only the actually required lamps are switched on, also setting the exact intensity needed. The UV LED lamps send information to the PLC, allowing system managers to achieve significant savings on energy costs. This makes the process truly sustainable from an ecological and economic point of view.

As mentioned above, a UV LED system requires virtually zero maintenance. The lamps last approximately 30,000 hours and without interruptions, production efficiency is boosted allowing for non-stop processing without any downtime and ensuring constant quality levels over time.

Why switch to UV LED lamps?

In a market scenario that is increasingly interested in UV LED curing techniques, the strategic elements in favour of this technology are mainly:

SUSTAINABILITY – operating and environmental safety is a key issue for future business success.

ADAPTABILITY – thanks to a wide and constantly evolving range of solutions, machinery manufacturers can now effectively customise their proposed solutions.

Cefla's expertise made available to companies looking for innovation

Cefla Finishing installed its first UV LED oven back in 2014, and has therefore been able to acquire and analyse technology-specific data for many years. With an installed base of around 200 units between wood panel coating lines and digital printers, the experience we have acquired to date is second to none in today's marketplace.

As a partner of Phoseon Technology, leading manufacturer based in Oregon, we can share our expertise based on 120,000 systems sold so far and 300 technology-specific patents. This makes our offer extremely flexible, but also allows us to provide consulting services based on our solid knowledge of different use cases and above all, on our systematic analysis of the data generated by countless implementations.

After all, this has always been Cefla Finishing's approach: listening to customers, understanding their business objectives and defining the most appropriate solution based on the key factors involved:

• environmental
• economic
• performance/production-related

The range developed over the years is so wide that it allows us to select the right UV LED lamps from a pool of different models, with different wavelengths and dimensions - catering for every need.

In particular, our UV-R LED ovens can be integrated into three types of lines:

• panel coating (new or retrofit solutions)
• panel coating incorporating excimer ovens
• industrial digital printing

Find out how we can help you make your business more efficient and innovative.

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Finding a way to match the finishing quality of your flat surface with the edge, especially when the market is looking for rounded edges and flat surfaces as part of the latest furniture trends, means you need to consider using the same paint and the same technique. Until today, this was just theoretical, but since we introduced Smartvacuum to combine with Smartedge, our vacuum coating solution for edges, it is now a reality.

Vacuum coating: sustainable and cost-efficient

Depending on the production volumes, with vacuum application technologies there are different solutions to coat the surface and edge of a panel. Outputs up to 1500 cabinet doors/shift can be handled with an island-type process dealing with:

• melamine sanding
• flat surface coating (Smartvacuum)
• edge coating (Smartedge)
• sanding prior to finishing

In-line processes are better for outputs exceeding 3000 cabinet doors/shift and can be either:

• melamine sanding
• panel surfaces coated in the Smartvacuum area
• panel edges coated in a 2-step process with Smartedge
• sanding prior to finishing

or for 6000 cabinet doors/shift as follows:

• melamine sanding
• in-line flat surface coating (Smartvacuum)
• all 4 panel edges coated using Smartedge
• sanding prior to finishing

Both Smartvacuum and Smartedge use 100% UV acrylic paints, avoiding release of solvents into the atmosphere. Processing times are reduced compared to alternative application technologies and less space is taken up by these machines.

Focusing on the edge coating process, we have developed patented solutions for Smartedge which are unrivalled on the market. EDGE&GO enables line operators to switch from one edge geometry/thickness to the next in no more than 15 seconds.

The dual function sanding unit for vertical corners with a radius and the flat section of a J-pull ensures compliance with the original radius and sanding of the excess product at the leading and trailing end of the handle.

The paint removal and panel cleaning unit seals the melamine between the flat part and the edge, recovers excess applied product and creates a perfectly flat panel surface. This prolongs the life of the abrasive paper in contact sanding machines, as wear is homogeneous over the whole surface.

The winning duo

The combination of Smartvacuum and Smartedge finally allows companies to streamline their coating process using the same technique and delivering the same top quality all round. It avoids pollution compared to spraying lacquers with solvents, it speeds up the process, reducing the handling necessities and, above all, cuts costs significantly.

Learn more about Smartvacuum in this webinar