The new installation developed by WAGNER allowed Shoemaker to automate and enhance its powder coating process.
Shoemaker, a manufacturer of air diffusers and heating coils, has used an advanced powder coating process
to colour its multi-layered metal parts. The initial painting process featured automatic booths for white and brown, while all other shades were applied manually. However, the increased demand for components in other shades has posed significant challenges for the Shoemaker. As a matter of fact, the manual involvement has changed the quality of the coating and the adequate powder extraction mechanisms have compromised the entire process.
Shoemaker decided to optimise its coating process, following these objectives:
- Automate coating of all colours with minimal transition times;
- Ensure consistent coating quality;
- Minimise rework;
- Improve dust extraction efficiency;
- Accelerate production speed and volume.
In nine months, the manufacture of equipment and systems for surface finishing WAGNER, has designed an innovative system - thus revolutionising Shoemaker's production methodology.
The white components are now coated in an expanded automatic booth equipped with SprayPackE. This application control system ensures flawless results while optimising material consumption. Furthermore, for all other colours, WAGNER has introduced the E-Line system with PXE powder centre, a compact and efficient system that combines superior coating quality and exceptional productivity. It also guarantees application efficiency, fast color transition times and an intuitive interface.
Shoemaker is satisfied with the investment, which has allowed it to achieve notable goals:
- Automated coating of all parts in a full spectrum of colours;
- 90% reduction in staff needed for rework during each shift;
- Increase in production up to 30%;
- Significant reduction in powder consumption thanks to intelligent powder recovery;
- Drastically improved efficiency thanks to automatic colour change.