Building Products Manufacturer, Automated Coating Process

A national building products manufacturer needed to modernize and upgrade its finishing process across multiple facilities.

Existing procedures relied on cart-based product movement, manual spray application, separate spray booths, and older, inefficient coating equipment.

Processes also varied from facility to facility, creating inconsistent production standards across the company's U.S. operations.

The client needed a more efficient, repeatable, and scalable approach that could support improved throughput and consistent coating performance across locations.

Grapek Bates Engineering and Application experts worked closely with the client's management team to develop a comprehensive design standard for facilities nationwide.

The integrated system included inline hanging conveyors, dual-station spray booths, dedicated feed and application equipment, integrated flash-off chambers, Air Make Up Units, and infrared automatic curing ovens.

Depending on each facility's requirements, the design also incorporated automated reciprocators and robotic application equipment to support higher consistency and efficiency.

All major equipment types were tied together through integrated controls, creating a coordinated coating process from product handling through application, flash-off, and curing.

Grapek Bates created a repeatable design standard that could be implemented across the client's facilities throughout the United States.

The automated process helped reduce reliance on manual handling and separate spray procedures, supporting a more consistent coating workflow from one location to the next.

Infrared automatic curing ovens allowed products to cure in a fraction of the time required by conventional ovens, helping improve production flow and overall efficiency.

The result is a scalable, full-system coating solution that continues to support modernization, standardization, and throughput improvement across the client's U.S. operations.