CASE STUDY
2026Automatic liquid paint coating system for heavy parts
Customer
Somefer
Objective
- In-source and double the production capacity of the paint shop
- Ensure high standards of aesthetics and protection to meet the requirements of leading European manufacturers
- Achieve maximum operational flexibility by managing different painting cycles on a compact production line
Challenges
- Ensure the safe, reliable, and precise handling of large components weighing more than 12.5 metric tons
- Optimize workflows by combining robotic automation, maximum repeatability, and fast cycle changeovers
Impact
The system engineered by Eurotherm meets the industry’s stringent quality and operational requirements, enabling Somefer to double its production capacity and ensure consistent, repeatable, and fully documentable results. Eurotherm’s design approach has made it possible to fully bring the finishing of the products in-house, eliminating downtime and optimizing the use of water-based raw materials, resulting in a significant reduction in waste and operating costs.
The implemented solutions are distinguished by:
- High-capacity material handling system based on shuttles and ground-based skids, designed by Eurotherm for the safe and precise handling of complex parts weighing up to 12.5 metric tons.
- Robotic automation on an 11-axis overhead carriage with a dual spray gun, which allows for the application of primer and topcoat with zero product changeover time and without the need for continuous circuit flushing.
- Environmentally friendly and efficient management of water-based products through a high-precision dosing system and electrostatic application, with mixing tolerances of less than one percent.
- Modular architecture with manual stations and independent ovens, designed to seamlessly integrate both standard finishing cycles and special processes such as embossing without causing delays.
High-Throughput Surface Preparation
The first phase of the process involves surface preparation of the components and structural handling along the line. After machining and automatic shot blasting to achieve a high degree of surface cleanliness, the workpieces reach the loading station. Eurotherm has developed a ground-based transport system using shuttles with skids attached to a roller conveyor, specifically designed to support and move exceptionally heavy loads exceeding 12.5 metric tons. This design ensures maximum stability and precision during positioning, incorporating a dedicated area for manual mechanical finishing and preliminary inspections before the components enter the actual painting zone.
Automated paint booth with advanced robotics
The second phase of the system centers on the Eurotherm automatic liquid paint booth. The application is handled by a Lesta robot suspended on an overhead carriage with 11 axes of motion, controlled via self-learning programming and dedicated CAD/CAM software. The key innovation lies in the use of a dual-gun configuration, which clearly separates the primer and topcoat lines. This technical feature allows for wet-on-wet application cycles with an intermediate drying time of approximately 15 minutes, eliminating interruptions caused by pipe flushing and avoiding the need to pass parts through the line twice.
Electrostatic Dosing and Application System for Water-Based Products
The third phase involves the control and feeding of coating products. In the technical room adjacent to the automatic spray booth, Eurotherm has installed an advanced system for managing water-based two-component products. Designed according to engineering standards derived from the automotive industry, the system utilizes an automatic electronic dispenser equipped with high-precision optical flow meters and direct-injection technology. Strict control of the catalyst ratio and a dosing tolerance of less than one percent ensure maximum repeatability and uniform electrostatic application to the component, guaranteeing full compliance with the established formulas.
Firing, drying, and dedicated lines for special treatments
The final stage of the cycle includes heat treatment for drying and the application of custom finishes. Once the automatic application of the paint is complete, the products pass through the curing zone and the main baking oven. To meet the specific needs of customers requiring specialized processes, such as high-density embossing used to even out surface finishes or mask imperfections in castings, the line designed by Eurotherm incorporates a manual booth for touch-ups and embossing, complete with its own independent drying oven. This flexibility ensures a seamless transition from fast standard processes to treatments that deliver exceptional aesthetic and functional results.
