Industries from agriculture to aerospace have been leveraging automation technology for decades. In recent years, the coatings industry has harnessed the power of automation with outstanding results. 

Automation technology—including AI, robotics, and other digital systems—has allowed companies to streamline processes, enhance productivity, and exponentially increase quality control. This type of technology allows us to further enhance the compelling properties and protective nature of coatings by delivering more accurate and productive applications. From increasing production capacity to the design of new coating formulations, automation has made a significant impact on the coatings industry. 

What is Automation?

Automation is defined as the use of largely automatic equipment in a system of manufacturing or some other production process. Today, this type of technology can be used for:

• Hardware, which can include machinery and control systems such as robotic spray booths or assembly lines.

• Software, which can include digital programs utilized to manage inventory, process orders, or run automated customer service chatbots.

• AI or machine learning, which can include using AI to analyze data, adjust formulations, schedule predictive maintenance, or make other business recommendations.

Efficiency and Productivity

One of the most notable impacts of automation on the coatings industry is a significant increase in productivity and output. Since automated systems do not require rest, they allow manufacturers or business owners to greatly scale up production and enjoy faster processing times. 

Systems that can look at the spray plume of a thermal spray process allow real-time feedback that can be used to adjust process parameters. This increases the laydown rate and deposit efficiency of the process, resulting in less time spent on part. With less gun time on part, you can spray without as many stops for cooling.

A more consistent coating thickness can also be achieved as automation delivers a more uniform application, a necessity within the aerospace and power generation industries. Thanks to advanced sensors and control systems, robots can adjust their movements in real-time, guaranteeing uniform coverage on a diverse array of surfaces. 

Cost and Material Savings

In today’s resource-starved economy, selecting a sustainable approach is always a win. Coating suppliers who have embraced automation are able to not only reduce labor costs but also keep material waste out of landfills. Automatic technology, like robotic spray arms, is an invaluable resource because its precise systems and calculations reduce overspray and the amount of coating material needed. Less material not only equals lower costs but also allows for more sustainable use of materials. Furthermore, lower labor costs can be achieved by robotics taking over repetitive and labor-intensive tasks, reducing the need for manual labor and associated costs. 

Safety and Environment

Another significant impact of automation is enhanced worker safety. The application of industrial coatings involves working in areas that can be dusty, loud, or hot, along with other substances that can harm workers during processing. Allowing robotics to handle this phase of the application process can minimize the risk of workers being exposed. In addition, robots are able to work in confined spaces or areas with little to no ventilation, thereby eliminating the need for human workers to enter hazardous areas and improving workplace safety. 

Quality and Innovation

Automation systems such as AI-powered tools and machine learning models are advancing the coatings industry through data-driven innovation. This technology can help industries develop new formulations faster and more accurately through the analysis of vast amounts of data. Automated systems can also learn from previous applications and self-adjust their settings based on the type of coating and surface being treated. Costly resources can be preserved as these predictive models discover trends or patterns in existing data and predict future coatings performance before any physical testing is performed. New and exciting formulations can also be created through reverse engineering the desired end-use properties, saving time and money. For example, scientists at Eastman recently leveraged AI to create an exceptionally durable polyester resin for can coatings.

Automation has indelibly made its mark on the coatings industry. This technology may seem like a rapid adjustment, but at its heart, automation simply provides a new way in which to capitalize on more opportunities. Whether you elect to operate under digital systems that allow you to manage your inventory with ease or you’ve automated your preventive maintenance schedule, the impacts of automation are bountiful. 

At HTS Coatings, we are steadfast supporters of any technology that allows us to protect our workers and increase our precision and productivity. That's why our 30,000-sq. ft. facility includes six robotic spray booths, and we utilize digital systems to support our employees and customers with safe coating applications and increased life. 

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