Painting process optimization

© Fraunhofer IPA

If paint processing companies want to remain future-proof, it is essential that they optimize their painting processes. The focus is on high quality, increased product volumes, improved environmental protection, energy efficiency and cost efficiency. Automation and digitization offer great opportunities to achieve these goals in the painting process. With a Quick Check and a Potential Analysis, painting companies can rapidly identify the savings & optimization potential of their painting process.

A Quick Check shows you where you can save money in your painting process

The Painting Process Engineering team answers this question swiftly and easily as part of a Quick Check with a Potential Analysis of your painting process. After a carrying out a survey of your paint shop, we give you prompt and expert information on weak points in your painting process and possible causes of defects. In addition to recording on-site conditions and identifying major weaknesses, our Quick Check includes the development of an initial action and optimization concept, a rough cost estimate and, if required, an outline of a possible alternative or new painting process.

In the event of a further order, the costs of any prior Quick Checks will be offset.

Get in touch with us today and make an appointment for a Quick Check by Fraunhofer IPA at your company!

Comprehensive analysis of processes and weak points with catalog of measures

Do you want to lastingly save energy and materials and reduce emissions? Do you want to use paints and solvents more efficiently? Or optimize your material recovery? Do you want to make your processes traceable and controllable through automation and digitalization? Or improve the quality of your painted components and avoid rejects? In short: Do you want to make your painting process more robust? We can show you how!

© Fraunhofer IPA
Analysis of spray patterns in paint shops
© Fraunhofer IPA
Valve block for changing paint automatically
© Linde Hydraulics GmbH
Paint dryer designed as a nozzle dryer

To identify and unlock optimization potential in your painting process, the first step is to set up a project team. Painting Process Engineering experts from Fraunhofer IPA, employees from your technical departments and, where appropriate, process engineers from paint suppliers and equipment manufacturers work together to find cost-effective solutions that can be implemented swiftly. The employees from your departments (e.g. from production planning, production, maintenance or quality management) form an important part of the project team and of the entire optimization process. The project is supported by a specially-developed software tool, comprising checklists, assessment methods and an extensive range of testing and measuring instruments.


Detailed procedure

  • When it comes to implementing optimization projects with complex general conditions, such as in a painting company, we intelligently combine recognized methods in the project. For example, we use the Six Sigma method to reduce the spread of errors and thus to lower reject rates. We also apply lean management approaches to align processes and avoid redundant activities. The four phases of the PDCA cycle are used for continuous improvement processes (CIP). By combining different approaches, we can identify suitable measures effectively and efficiently.

  • Scope for recording the actual state according to Fraunhofer IPA standards, including:

    • Composition of the parts spectrum
    • How parts are arranged on product carriers (conveyors)
    • Description of the paint shop
    • Material flow
    • Specific paint data
    • Key data on the paint application process
    • Energy consumption
    • Water management
    • Painting process costs
    • Current requirements
    • Specifications
  • The basis of the weak point analysis to determine the savings potential is the on-site inspection of the company. The analysis is based on empirical results as well as specific measurements and tests. Among others, the following parameters can be determined and analyzed:

    • Spraying parameters
    • Order efficiency
    • Paint shop capacity
    • Air conditions in spray booths
    • Material flow
    • Required paint layer structure
    • Paint layer thickness and distribution
    • Energy management and energy analysis
    • Rework statistics
    • CO2 footprint

    To evaluate the actual conditions and assess optimization options as well as efficiency measures, we prepare a detailed requirements catalog and a trend analysis.

    Based on this, a catalog of measures is compiled, priorities are set, and deadlines defined. Fraunhofer IPA also assists companies in implementing these measures and monitors the progress made towards achieving company targets.