All there is to know about vacuum coating solutions

Vacuum coating is an application technique that boasts extremely high transfer efficiency, almost 100%. This means perfect control over lacquer consumption, little or no waste, excellent quality at relatively low costs. Once used exclusively on edges, vacuum coating solutions now exist for flat panels such as cabinet doors or bathroom furniture.

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Vacuum coating

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How does vacuum coating work?

Vacuum coating is a sustainable alternative to other coating techniques because it employs a 100% solid UV product, which is also more stable than polyurethane o polyester-based lacquers over time. It avoids contact between the application head and the substrate for clean, single-pass processing of 100% UV acrylic paint. Depositing up to 140 g/sqm this technique also helps reduce the number of coating stages when applying a basecoat, thereby saving workshop floorspace and improving lead times as well as limiting the number of handling operations needed.

benefits

The benefits of vacuum coating technologies

Further to the superior transfer efficiency offered by this technology, there are more specific advantages according to what the goal is. For example, panels with rounded edges can be coated using vacuum coating equipment, both for the surface and the edge. Moreover, the sanding process can be fully integrated into the edge coating machine or the line as a whole.
We have pioneered vacuum coating as an application technique because it ensures a significant number of benefits:

Using a solid UV lacquer, vacuum coating delivers a ec-friendly, longer-lasting, high-quality finish.

Superb transfer efficiency reduces costs, shortens lead times and boosts production output.



Same technique for both leads to a perfect match and the absence of an ugly junction seam.

Depositing large lacquer quantities in a single pass and integrating sanding capabilities reduces coating stages and handling operations.

Where can vacuum coating technologies be used?

Vacuum coating is a valid alternative in the following industries and for the following substrate materials:

Materials

Sectors

Campi di utilizzo

Some specific application areas and products finished with vacuum coating

APPLICATIONS

01

Flat doors

Managed on roller coater and curtain coater lines, doors can also be processed on an overhead line using anthropomorphic spray-coating robots and in-line drying solutions using hot-air ventilation.
02

Flat panels

Flat panels can be of many different substrate materials, from wood to plastic, metal or ceramics. Usually coated on roller coating equipment, curtain coaters, industrial digital printers, vacuum coaters and spray coaters can also be used.
03

Panel edges

These can be finished using vacuum coaters to obtain a perfect match with the surface, or can be wrapped with material decorated on an industrial digital printing machine.
04

Acoustic foam panels

Sealed at the edges using vacuum coating technology, these panels can also be painted using a spray coater, especially if they will be exposed and visible.

Focus On

Vacuum-JPULL

Perfect junction seams

Avoiding the ugly junction seam caused by the difference resulting from the coating techniques used for edge and panel surface is a priority for furniture manufacturers. By using vacuum coaters for both sections, this seam virtually disappears, leading to an improved panel finish, with a soft touch on its rounded edge.

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VacuumEdge&Go

Double dispensing vacuum head

Recently launched, this new application head enables the Smartedge edge finishing machine to apply between 150 and 180 g/sqm. increasing capacity by approx. 50%. Moreover, a special blade helps the applied product to penetrate fibreboard parts ensuring maximum sealing performance.

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process

The vacuum coating process

Vacuum coating applies lacquer or a sealing agent in a single pass without the application head having any contact with the substrate (flat surface or edge). Transfer efficiency is almost 100%. Until recently, this technology was used for edges, coating, sealing or even waterproofing. Today, vacuum application solutions are a valid alternative for flat panels as well as edges.

Discover the vacuum coating equipment for surface coating applications as well as impregnation and sealing

Products

Smartvacuum

Materials:

  • Wood
  • Fibre Cement

Machine Type:

  • Vacuum Coating

Smartedge

Materials:

  • Ceramic
  • Wood
  • Mineral Fibre

Machine Type:

  • Brushing and Sanding
  • Ovens
  • Curtain and Roller Application
  • Handling
  • Vacuum Coating

Talent

Materials:

  • Plastic
  • Metal
  • Wood

Machine Type:

  • Vacuum Coating

Talent Sigma UV

Materials:

  • Plastic
  • Metal
  • Wood

Machine Type:

  • Vacuum Coating

CVR Vacuum IR Finishing System

Materials:

  • Plastic
  • Metal
  • Wood
  • Fibre Cement

Machine Type:

  • Vacuum Coating

CVS Vacuum UV Finishing Line

Materials:

  • Plastic
  • Metal
  • Wood

Machine Type:

  • Brushing and Sanding
  • Ovens
  • Vacuum Coating

Case studies

Case study

We have helped hundreds of companies around the world achieve their quality, efficiency, and productivity goals. Here are their stories.
We have helped hundreds of companies around the world achieve their quality, efficiency, and productivity goals. Here are their stories.
01

A complete moulding finishing line for TLC Mouldings

02

No more machine downtime for Pianca thanks to automatic colour changeover

03

Holzexport to focus on technology tripling its output potential

WHITEPAPER

The most innovation finishing solutions

New finishing solutions: more effective, more productive and more competitive than those currently in use.

Download the white paper

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MAGAZINE

Explore the topic on our blog. You can find articles on technologies, innovative techniques, and tips to improve the efficiency of your finishing line.
Explore the topic on our blog. You can find articles on technologies, innovative techniques, and tips to improve the efficiency of your finishing line.
01
    Vacuum coating

Is vacuum coating an environmentally friendly process?

02
    Edge Coating

Here comes another edge. Downtime or more time?

03
    Vacuum coating

Smartvacuum: improving the basecoat application process

04
    Vacuum coating

How can vacuum finishing technology reduce my cost per-piece on mouldings and linear profiles?

05
    Vacuum coating

Vacuum coating technologies: superior transfer efficiency

The largest range of surface finishing solutions the world knows, developed in over sixty years serving the industry.

We provide expert advice on coating technologies, profile wrapping and lamination equipment, drying systems and all other ancillary surface finishing solutions. Experience across several industrial sectors, we are a trusted source and partner who can help you achieve your business objectives.

Tell us where you want to go and our finishing experts will help you get there.

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Frequently Asked Questions

Frequently Asked Questions

01 Which substrate materials are suitable for vacuum coating?
Vacuum coating is suitable for wood and its derivatives, metal, plasterboard, composite materials and PVC profiles.
02 This technology is perfect for the coating of…?
This technology is ideal when coating lineal profiles in high volumes, achieving high levels of production efficiency.
03 What are the advantages of vacuum coating?
This technology has many benefits. To start with, transfer efficiency reaches an astonishing 99%. Vacuum coaters have a limited footprint, so they occupy little factory space. Production efficiency is optimised because by using a vacuum coater, 360° sanding, coating and curing of a profile is dealt with in a single pass. Overspray is absent and the process is environmentally friendly. Coating thicknesses are high and, for example, can reach 700 µm on glass wool panels.
04 How can I measure coating quality?
This is an aspect that can primarily be evaluated subjectively. However, where rigidity is a required characteristic of the coated object, this technology enables high coating layer thicknesses (e.g. 700 g/m2 in the case of ceiling tiles) by using paints with 80% solids, leading to further benefits in terms of reduced drying costs. Constant coating thickness is also a key quality achieved with vacuum coating techniques, even in the case of complex profiles.
05 What are the size limitations for pieces that will be vacuum coated?
The minimum length is 915 mm (36”) and the maximum width is 305 mm (12”). Any size between these two limits is possible.
06 How long does it take to clean a vacuum machine?

Cleaning times vary according to the size of the machine and the type of paint being used. Water-based paints require less time than viscous UV lacquers. On average, when changing profiles, it will take between 10 and 15 minutes. If you are also required to change colour, this will take up to 30 minutes.

07 Can coating consumption be controlled?
Yes. By adjusting the template opening, vacuum pressure and speed of the coating line, you can control the coating thickness, thereby affecting coating consumption. Paint viscosity is temperature-controlled in the case of UV lacquers and according to the formulation of water-based paints. This also affects overall consumption.
08 What do I need apart from the vacuum coating machine to complete the process?
To make the process smoother, you can add infeed and outfeed conveyors. In any case, our solution is a fully integrated one comprising material preparation, application and drying. Edge-coating units are often installed in existing double-end tenoners for more precise workpiece guidance and consequent absence of overspray.
09 How flexible is the machine?
As vacuum coating is suited for large volumes of the same or similar type of profile, flexibility is not a key feature of machine or process. When the profile changes, the user simply has to change the template or painting head.
10 Can we say that vacuum coating is a sustainable process?
Yes. As the system handling the vacuum coating process is fully encapsulated, zero coating waste is possible, making this one highly sustainable aspect. Furthermore, you can use solvent-free coatings and the design of vacuum coating systems today enables users to minimise energy consumption. Machines have a 1.2 kW power output.