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2025
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Need a Flexible Coating Line for Small-Batch, Multi-Color Production?
Author：
Chuangzhi Coating
Small-batch, multi-color customized production is becoming a new trend in manufacturing, but traditional coating lines often "break down": changing a color requires disassembling the spray gun and cleaning the pipeline, taking more than 40 minutes; if there are more than 5 changeovers a day, the production is trapped in the dilemma of "spending half a day on changeovers"; color residue leads to mixed-batch defects— a hardware enterprise once lost more than 30,000 US dollars due to red paint residue contaminating silver workpieces; small-batch orders require batch accumulation for production, extending the delivery cycle to 15 days and increasing customer churn. To address these pain points, our flexible coating lines, centered on multi-color rapid changeover coating systems and combined with the flexible adaptability of small-batch coating equipment, turn small-batch, multi-color production from a "burden" into a "competitive advantage".
1. Multi-Color Rapid Changeover Coating Systems: Complete Color Switch in 8 Minutes
Color change efficiency is the core competitiveness of flexible coating lines. Our system achieves a changeover revolution through "hardware upgrading + process optimization":
A modular paint supply unit is adopted, with independent sealed paint tanks and dedicated pipelines for each color to avoid cross-color contamination; the spray gun is equipped with an automatic cleaning valve group, which automatically rinses the gun body with high-pressure solvent during changeover (cleaning time ≤90 seconds). Combined with on-line pipeline purging technology, the residue is controlled below 0.1ml; the system has a built-in color memory function, with one-click calling of parameters for more than 50 commonly used colors, eliminating the need for repeated manual debugging. After application by a home appliance accessory enterprise, the changeover from white to black takes only 6 minutes, and the daily production capacity of 150 pieces per hour is still guaranteed even with 12 changeovers a day, which is 3 times more efficient than the traditional line.
2. Small-Batch Coating Equipment: Precisely Adapting to "Diverse and Small-Batch" Needs
The pain point of small-batch production lies in "diverse workpieces and small batches". Small-batch coating equipment breaks the constraints through intelligent adaptation technology:
Equipped with a 3D visual scanning system, it can automatically identify workpieces of different sizes (from 5cm small hardware to 1.2m home appliance panels) and complete the coating path planning within 10 seconds, without manual programming; a 6-axis collaborative robot is adopted with a repeat positioning accuracy of ±0.1mm, achieving dead-angle-free coating for hidden areas of special-shaped workpieces (such as curved brackets and porous shells), and the coating thickness deviation is stably maintained within ±2μm; a flexible conveyor line is equipped to support one-piece flow production, and the minimum batch of 10 pieces can start coating without waiting for batch accumulation. A customized furniture enterprise thus shortened the delivery cycle from 15 days to 5 days.
3. Flexible Coating Lines: Dual Optimization of Environmental Protection and Cost
Small-batch production is prone to the misunderstanding of "high cost and high emission". Flexible coating lines achieve cost reduction and compliance through full-process design:
A closed-loop supply system for low-VOC coatings is adopted, increasing the paint utilization rate from the traditional 60% to 92% and reducing the paint loss per piece by 40%; the end integrates a miniaturized treatment device of "paint mist filtration + activated carbon adsorption" with an area of only 2㎡, and the VOCs emission concentration is ≤25mg/m³, meeting the GB 37822-2019 standard; the intelligent energy consumption management and control system can automatically adjust the equipment power according to the batch, reducing energy consumption by 30% during small-batch production. After application by a hardware enterprise, the coating cost per piece decreased from 1.2 US dollars to 0.7 US dollars, saving more than 280,000 US dollars annually.
Case: From "Changeover Anxiety" to "Order Freedom"
A precision instrument accessory factory was once troubled by traditional coating lines: 30 color switches led to changeover time accounting for 40% of the total, and the profit of small-batch orders was eroded by high losses. After introducing our flexible coating line, the multi-color rapid changeover coating system shortened the changeover time to 7 minutes, and the small-batch coating equipment realized flexible production with a minimum order of 10 pieces; combined with AI visual inspection, the defect rate dropped from 10% to 0.6%. After the transformation, the enterprise not only undertook customized orders from a high-end brand but also increased the capacity utilization rate from 65% to 90%, with an annual revenue growth of 45%.
Full-Process Customization Services: Your Exclusive Flexible Production Solution
We reject "one-size-fits-all" solutions and provide full-cycle services from demand diagnosis to after-sales operation and maintenance: in the early stage, the technical team visits the site to survey and design an exclusive flexible coating line plan according to the number of colors (such as 20 commonly used colors), workpiece size, and daily production capacity (such as 1,000 pieces/day); during the installation stage, engineers are stationed on-site for commissioning and train the operation team to master changeover and equipment maintenance skills; after-sales service includes 1-year free maintenance, equipped with a remote fault diagnosis system that responds to problems within 30 minutes to ensure uninterrupted production.
Conclusion
Small-batch, multi-color production is not a "niche demand" but an inevitable trend in manufacturing upgrading. Flexible coating lines solve the changeover problem with multi-color rapid changeover coating systems and adapt to diverse needs with small-batch coating equipment, helping enterprises seize opportunities in the customized market. Whether you produce hardware accessories, home appliance panels or precision instrument casings, we can create an exclusive plan. Consult now to make the flexible coating line your "order-taking tool" and achieve high-profit growth in the small-batch market.
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