The planning of a coating system forms the foundation for successful project execution and long-term operational performance.

Every stage of a project requires meticulous planning. Whether it involves a feasibility study, the implementation of a new powder coating or liquid paint system, or the relocation of an existing facility, careful planning is a key success factor.

Many people believe that project management is the most important aspect when building an industrial coating plant. While project management is undoubtedly essential, we consider the planning phase before implementation to be even more critical. The different project phases can be compared to states of matter:

Gaseous: In this phase, maximum flexibility exists, and a wide range of ideas and concepts are evaluated. Different variants are assessed, and innovative solutions are developed.

Liquid: At this stage, the project takes shape. Concepts are transformed into calculations, layouts and technical plans. Contracts are negotiated and finalized. Adjustments and optimizations are still possible.

Solid: The coating system is being manufactured and installed. Modifications become increasingly difficult and costly. Planning errors at this stage can have significant consequences.

For this reason, we place particular emphasis on the conceptual design of every coating plant and surface treatment system, ensuring that project success is established from the very beginning.

OUR 8-STEP PRE-PROJECT PLAN

1. DETAILED ANALYSIS:

We analyse production processes, material flows, product ranges, logistics and operational requirements to gain a comprehensive understanding of the project environment.

2. CALCULATION OF OPERATING COSTS:

Using our proprietary tools, we calculate future operating costs and evaluate existing operating expenses to establish a reliable basis for decision-making.

3. CUSTOMER BENEFIT ANALYSIS:

Based on collected data, optimization points are identified, and potential opportunities are quantified.

4. VALIDATION OF SAVINGS POTENTIAL:

A comparison between the current and target state highlights expected savings, efficiency improvements and potential project risks.

5. PROFITABILITY ANALYSIS:

An initial assessment of the economic viability of the project is carried out, including investment and lifecycle considerations.

6. PRESENTATION OF ALTERNATIVE SOLUTIONS:

There is rarely only one solution. Through iterative development and alternative concepts, we work together to identify the optimum solution.

7. BUSINESS CASE EVALUATION:

For financial decision-makers, we prepare key performance indicators such as cumulative lifecycle savings, Internal Rate of Return (IRR), Net Present Value (NPV) and Payback Period

8. PRESENTATION OF RESULTS:

All results are documented in a clear and structured report for management, board members or stakeholders. A comparison of alternatives provides a solid basis for informed decision-making.

Simulations

PinCH

Thermal simulations provide valuable insights into energy consumption, heat recovery potential and process optimization opportunities within industrial coating systems.

Learn more: PinCH analysis 

SimLack

Our proprietary simulation software analyses complete coating systems with a particular focus on conveyor technology and material flow. Unlike conventional simulation tools, our approach emphasizes physical process behaviour rather than graphical representation.

The simulation of the coating system enables proof of concept validation, identifies bottlenecks and weaknesses, and allows potential issues to be evaluated before implementation. This helps develop effective solution strategies while minimizing project risks.