Greenfield is proud to showcase our new paint plant, a fully integrated pre-treatment and paint line designed to enhance efficiency, quality, and process control across powder coating operations. The installation brings together advanced pre-treatment, curing, powder application, safety, and chemical management systems from established industry recognized suppliers.
The five-stage pre-treatment line, supplied by TD Finishing, incorporates automatic degreasing, rinsing, silane coating, and final rinse with dry-off. The system features automatic chemical dosing and an in-line conveyor operating at up to 2,000 mm per minute, ensuring consistent surface preparation prior to coating. Curing is managed by a high-temperature powder oven with an automatic heat recovery control system and remote temperature monitoring, also operating on an in-line conveyor at 2,000 mm per minute. This provides controlled and repeatable curing conditions across production runs.
Powder application is delivered through a Wagner S-Line automatic powder coating system housed in an M-Cube plastic booth with 1,000 lux illumination. The system includes high-capacity powder recovery, combining a 21,000 Nm³/h suction unit with a MonoCyclone rated at 16,000 Nm³/h. The flow-optimized design reduces energy consumption of the after-filter by up to 40 percent compared with conventional systems. An integrated IPS Powder Supply Coating Centre enables fully automated powder supply and colour changes using Smart Feeding Technology, supporting consistent powder flow with reduced wear over extended operating periods. Application is carried out using six PEA-X1 automatic guns and two Sprint 2 Expert MPS manual guns. The system control is managed via Wagner’s WICOS plus platform, providing an all-in-one control and operating system for the entire powder coating process. An integrated Machine Data Hub with OPC UA interface allows remote access to process data, including system status, coating parameters, and colour change times. Workpiece detection scanners automatically control gun activation, adjusting to component height and geometry across 32 height segments to improve application efficiency and reduce powder consumption.
The physical system safety is addressed through an automated CO₂ fire detection and suppression system supplied by STS, compliant with EN50177 safety category 3. The system includes flame detection, alarm and control panels, and a complete CO₂ extinguishing setup with monitored release mechanisms.
The pre-treatment chemical management is provided by Henkel an industry leading chemical supplier with an automatic dosing system, incorporating dual LDS panels with conductivity and pH monitoring for precise control of cleaning and conversion stages. The system supports remote monitoring and data capture for analysis and production records, ensuring consistent chemical control throughout the process.
Together, the online paint plant represents a comprehensive, automated solution focused on quality, energy efficiency, process transparency, and operational safety.
