Challenges
  • Develop a comprehensive powder coating solution ensuring strict control from input preprocessing to output drying to achieve the best quality coating.
  • Complete the entire production line within six months to start production, involving a significant volume of work.
  • Ensure the line operates stably across three shifts daily, meeting an annual capacity of 3 million products.
Keys to Success
  • Leading the trend by adopting the world’s most advanced automation applications in the coating industry.
  • ETEK’s experienced engineers continuously improve their capabilities.
  • Collaboration with reputable and experienced partners.
  • Organized implementation through transparent, refined processes from numerous successful projects.
Results
  • Successful development of an automated coating line suitable for client’s various product models. The line operates stably, efficiently, and safely.
  • Met the client’s project timeline and exceeded initial expectations.
  • Mastered core automation technologies in the coating are applicable to various products

Automated Powder Coating Line for Metal Components in Automotive Manufacturing

Challenges and Client Requirements

As many processes in the factory had successfully implemented automation, enhancing production efficiency significantly, the coating process became the next focal point for our client. Coating is an indispensable link in the value chain to improve the overall productivity of the factory and increase production autonomy.

Not only ensuring the synchronization of the entire factory but also applying automation in the coating process brings numerous advantages, such as optimizing materials, reducing waste, and maximizing resources.

The challenge was to build a fully automated powder coating line, meeting criteria such as:

  • The layout is compatible with the current factory layout.
  • Compliance with the standards of Vietnamese law, the client, and relevant organizations.
  • Ensuring continuous, safe operation and meeting productivity demands.
  • Durable and aesthetically pleasing paint quality.
  • Flexible application across various product models.

In this journey, ETEK acted as a solution provider and a reliable partner, always ready to face any challenges with the client. With creativity and determination, we are committed to delivering optimal solutions at every stage, helping our clients realize their goals and achieve sustainable success.

Technology Leadership – Partnering with Clients

With over 20 years of experience in construction and development, we have applied our in-depth expertise in collaboration with the world’s leading partners in the coating field. We have delivered solutions that fully meet their requirements and are committed to closely accompanying our clients.

Furthermore, we proactively proposed better alternatives and replacement solutions. All aimed towards our core objectives: QUALITY – SCHEDULE – COST OPTIMIZATION – SAFETY.

Core Technologies Enabling Our Success in This Project:

  • Pre-coating processing technology: A crucial step directly affecting the durability and appearance of the coating. We applied an 11-step pre-treatment technology, ensuring the product was completely cleaned of dust, chemicals, etc., before entering the coating process.
  • Electrostatic powder coating technology: The paint is uniformly sprayed over the product surface using automatic painting robots. The paint layer is durable and visually appealing. The system integrates features to recover excess paint for reuse.
  • Post-coating treatment technology: Products are placed in a drying oven to cure after coating. The oven ensures suitable temperatures and has a system to monitor and adjust temperatures appropriate for the products.

Thanks to the synchronized application of these technologies, we delivered a comprehensive production solution, contributing significantly to the project’s success.

Challenges During Implementation

The short deployment time and a considerable workload presented significant challenges that ETEK had to overcome to ensure the project was completed on schedule. A single hiccup could seriously affect the project timeline, necessitating tight coordination and close monitoring of each phase.

ETEK understood that we needed help to complete this large-scale project. Therefore, choosing the right partners played a crucial role. We conducted thorough assessments, from technical capabilities and practical experience to commitment and coordination abilities in the project. Effective collaboration among parties helped minimize risks and optimize resources.

ETEK is committed to overcoming all difficulties to realize shared goals with a flexible approach and synchronized cooperation with reputable partners. The project was a challenge and an opportunity to affirm ETEK’s capabilities and collaborative spirit in deploying advanced technological solutions.

Achieved Success

We successfully developed an optimal powder coating solution, launching the production line in time to meet production demands. The line operates continuously and safely, helping the factory meet its initial requirements.

We continuously learned from our clients and partners to improve during the project implementation. We confidently mastered the core technology to meet similar requirements.

Additionally, through the project, we built an ecosystem that included ETEK and expert units in the coating field, ready to deploy any related requirements confidently.

Plans for the Future

Following the success of the electrostatic powder coating line, our client continued to expand automation for various parts and materials used in automobiles and motorcycles, promising to bring automation closer to every factory.