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2026Paint Shop Revamping: Performance, Efficiency, and Energy Savings
When a coating system can no longer meet new production requirements, the solution is not necessarily to replace it entirely. In many cases, a targeted upgrade allows for the renewal of the most strategic technologies, improves line performance, and increases process efficiency. This is the approach Eurotherm chose for a leading company in the field of high-quality coating, with a specific goal: to achieve higher process temperatures while simultaneously reducing energy consumption. The result is a higher-performing, faster, and more efficient system, designed to ensure production continuity and long-term performance.
The challenge: renovating the facility without starting from scratch
The customer had a clear and specific need: to upgrade the drying and curing ovens, adapting the new components to the fixed dimensions of the existing line and the available space in the plant.
The Eurotherm Solution: Updated Technology, Enhanced Performance
For the plant’s retrofit, Eurotherm chose a solution focused on process efficiency and sustainability. The core of the project was the replacement of the old furnaces with new units based on air-channel technology, which replaced the traditional combustion chamber. This decision made it possible to meet the process’s new thermal requirements while simultaneously achieving greater energy savings. The project thus transformed a limitation of the existing plant into a concrete opportunity for improvement, without unnecessarily modifying the parts of the line that were still operating efficiently.
The main initiatives:
- New drying oven: designed to adapt the process to new production requirements and achieve more efficient processing conditions.
- Old powder-firing kiln operating at 200 °C: replaced to ensure that the temperatures required by the new treatment cycle are reached.
- Air-flow technology: incorporated into the new ovens to increase efficiency and reduce energy consumption compared to the previous configuration.
- Automatic conveyor retained: The existing system was integrated into the new setup, avoiding the replacement of a component that was still serviceable and focusing the investment on technologies that truly needed to be upgraded.
Get in touch
Do you have a paint shop that needs to be modernized? Contact Eurotherm to work with our experts on designing a customized revamping project.
Faster speeds, lower fuel consumption: the value of technological integration
The project was not limited to the renovation of the kilns. To further reduce processing times, Eurotherm installed a pre-gelation chamber equipped with gas-fired IR radiant panels at the entrance to the firing kiln.
The result is immediately measurable: the line speed has increased from 1–1.2 m/min to 2 m/min. In other words, the powder coating process has been doubled in speed, resulting in increased productivity while significantly reducing energy consumption.
Why Choose to Revamp a Paint Shop?
A well-designed revamping project is a practical strategy for improving the performance of an existing plant. It is not simply a matter of replacing obsolete components, but of rethinking the process by identifying the technologies that can have the greatest impact on productivity and efficiency. A thorough redesign of the paint shop allows for:
- Adapt the production line to meet new process requirements by introducing technologies capable of reaching the required temperatures.
- Increase productivity by focusing on the parts of the process that have the greatest impact on processing times.
- Reduce energy consumption by adopting more efficient technologies and implementing more flexible control of the polymerization process.
- Optimize the investment by keeping existing components that are still efficient in operation and focusing the upgrade on the truly strategic elements.
The result is a more modern, high-performance, and efficient painting system capable of meeting new production requirements while retaining some of the original components. This experience also confirms a core principle in industrial plant design: a targeted intervention, when supported by a thorough technical analysis, can significantly improve the line’s performance and generate tangible benefits in terms of both production and energy efficiency.
Why Choose to Revamp a Paint Shop?
Today, modernizing a painting system means looking beyond simply replacing technology. It means increasing production capacity, improving efficiency, and reducing energy consumption through solutions designed around the actual needs of the process. With this project, Eurotherm has transformed a plant whose performance had become limited into a faster, more efficient line that is ready to meet new production demands.
Get in touch
Do you have a paint shop that needs to be more efficient or can no longer meet the demands of your process? Eurotherm can analyze your existing setup and design a revamping project focused on performance, productivity, and energy savings.