Industry 4.0 coating plants: Cefla’s pivotal role

Digitalization has reshaped the way we manufacture: machines that communicate with one another, real-time data harvesting and self-regulating processes are no longer the exception but the standard towards which the entire manufacturing sector is moving. In this scenario, even the surface finishing sector – traditionally perceived as “artisanal” – has undergone a profound change.

Coating plants for Industry 4.0 exemplify this evolution: production lines on which automation, sensors and connectivity work together to ensure greater efficiency, consistent quality, and full process control, while reducing waste and energy consumption. The goal is not simply to automate but to make every stage, from coating application to drying, measurable, repeatable and integrated with the rest of the factory.

In this article, Cefla provides a comprehensive overview of the topic and explores the role the Cefla Finishing Business Unit plays in this transformation.

What does industry 4.0 mean for industrial coating facilities?

Any discussion about Industry 4.0 in the coating sector means moving beyond the concept of simple automation. An automated line performs tasks without manual intervention while a 4.0 coating plant goes one step further: it gathers data, interprets it and adapts the process accordingly, communicating with the rest of the factory. It’s the difference between a machine that works on its own and a plant that works intelligently.

At the heart of this transformation lies connectivity. Every Industry 4.0 industrial coating plant relies on a network of sensors distributed along the production line. These measure process parameters such as film thickness, speed, drying temperatures and product consumption, in real time. This data is transmitted to the control levels, where PLCs (programmable logic controllers) process it and compare it with the production targets, and to the supervisory systems, which coordinate the entire line and allow it to be monitored remotely. It’s a two-way flow: instructions come from above, and information flows up from below. This integrated architecture, extending from the “field” of machines all the way up to the company’s management systems, is what distinguishes a truly Industry 4.0 facility from a merely modern production line.

User-friendly HMIs translate the complexity of the data into easily understandable commands while Industrial Internet of Things (IIoT) logic lets you interconnect a single machine or an entire line and, if necessary, export data to the cloud. The result is a plant that not only produces but understands itself: it knows how, how much and how efficiently it is working, and makes this information available to those who have to make decisions.

The benefits of a 4.0 coating plant

Digitalizing and connecting a coating line is not a technological endeavour for its own sake: it translates into tangible, measurable benefits that directly impact costs, quality and competitiveness. The main advantages are:

• Greater production efficiency: continuous monitoring and automatic adjustment of parameters reduce machine downtime, idle time, and manual reconfigurations, increasing the volume of material processed in the same timeframe. Changing batches (colour, thickness, formula) is quick and does not require emptying or stopping the line.
• Consistent, repeatable quality: by monitoring variables such as thickness, speed and drying temperatures in real time, the plant ensures a uniform finish on every piece, reducing waste and rework.
• Reduced waste and consumption: vision systems, air control and product recovery limit overspray and coating loss, resulting in direct savings on materials and disposal costs; this also delivers a sustainability benefit.
• Predictive maintenance: analysing operational data allows you to take action before a failure occurs, enabling you to schedule maintenance and avoid unexpected and costly downtime.
• Complete traceability: every batch, and even individual pieces, can be tracked throughout the entire production line. Data is shared with the company’s management systems, giving total control over the process.

The advantages of this plant, however, do not depend solely on the technology installed but on those who design and fine-tune it according to actual production needs. This is where the expertise of a specialized partner comes into play.

Cefla’s role in Industry 4.0 coating plants

From this perspective, Cefla Finishing set the international standard. A Cefla Group Business Unit and a world leader in surface finishing – from wood to glass, from plastic to metal – it designs and builds custom coating plants and turnkey solutions, implementing the principles of Industry 4.0 on real production lines.

The machine pool developed by Cefla Finishing is controlled via PLCs and HMIs: this makes it possible to connect a single machine or an entire line to the factory’s IT systems and, when required, export data to the cloud. The company’s true area of expertise is programmable automation: the machines manage set-up recipes that store all the optimal parameters for each product type and instantly retrieve them when the batch changes. The spray booths apply specific coating recipes, the ovens adjust the drying phases accordingly and the entire line reconfigures itself quickly without interruption.

This approach translates into tangible results for customers. Thanks to a finishing line equipped with an exclusive Cefla Finishing-developed innovation that reduces coating consumption and eliminates the downtime normally required for colour changes, Finver has achieved savings of approximately €25,000 per year on coating costs while reducing disposal expenses. In another case, the adoption of automated and connected solutions enabled HIB to increase production volumes by 20%. These figures demonstrate that a well-designed Industry 4.0 coating plant always delivers a measurable return in terms of efficiency and competitiveness.

But the machines are only part of the value that Cefla Finishing offers. Completing the offering is a digital ecosystem designed to support the line throughout its entire lifecycle.

UBIQUO: the digital ecosystem strengthening the line

UBIQUO is the suite of services and software solutions through which Cefla Finishing connects people and machines, bringing together the physical, digital, and virtual dimensions to ensure the highest level of support, efficiency, and predictability. At its core lies cSuite, a selection of software tools that support the plant at every stage, from design to daily production.

The process begins even before the line is installed, with cCloner: software that simulates production and configures the line correctly, estimating coating and energy consumption, process times and the coated surface area in advance. It is, in fact, a digital twin that allows you to evaluate a plant’s performance even before it is built, thereby reducing the risks associated with the investment.

Once production begins, cTracker comes into play. This tool tracks and monitors the entire line from a single point. It collects all the data and, thanks to cLink, shares it with the company’s management software; it allows for quick adjustments to parameters based on new colours and thicknesses and enables tracking of an entire batch or even a single piece, without having to stop the line every time production changes.

Lastly, cMaster ensures constant monitoring over time. Wherever you are, all you need is an internet connection and a tablet or smartphone to monitor the status of one or more lines in real time: cMaster provides data and statistics that are useful for planning preventive maintenance and allows Cefla Finishing technicians to supervise the line remotely, enabling increasingly proactive support.

It is the combination of these elements that defines Cefla’s role in coating plants for Industry 4.0: not merely a supplier of machinery, but a partner who accompanies customers throughout their transformation journey. To find out how to apply these solutions to your production facility, contact the experts at Cefla Finishing.