Production process optimization plays a pivotal role in improving cost efficiency, reducing waste and boosting product quality. Manufacturers in the finishing sector can - by implementing advanced technologies such as integrated coating lines, robotics and digital printing - streamline workflows, minimise bottlenecks and achieve greater processing precision.

First of all, we need to clarify something: the principles and tools of so-called lean manufacturing will only generate the anticipated benefits if there is a broad, cohesive strategy, of which the technological aspect is just the tip of the iceberg.
To take quality to the next level, it’s simply not enough to purchase the latest-generation machines. In addition to identifying and eliminating low-added-value activities - with a view to shortening time-to-market without losing control of operating costs - it’s necessary to adopt sustainable practices such as recycling waste materials and using eco-friendly finishing agents. Strengthened relationships with suppliers and employees are equally vital. Additionally, investment in training promotes a culture of continuous improvement, allowing the industry to respond flexibly to market demand and truly benefit from innovation.
What is production process optimization?
Any organisation intent on optimizing its production processes needs to prioritise along three lines: eliminating inefficiencies, reducing costs and improving quality.
In the finishing industry, the most innovative companies have already drawn up and followed ‘roadmaps’ with three main branches: specialised coating processes, automation and digital printing.
Optimizing spray coating processes, for example, largely involves implementing recirculation and rotation systems on the production lines. At a stroke, this approach diverts skilled labour away from menial tasks and reduces the risk of inefficiencies and bottlenecks. Cost reduction, instead, is achieved by installing machines with fast yet simple colour changeover systems that continue to deliver the same high performance without increasing energy or material consumption.
It’s also possible to deploy systems that introduce roller coating techniques. The latter combine excellent manufacturing flexibility - the result of an extremely wide range of applications and good consistency - with minimal solvent emissions thanks to the use of products that, in 95% of cases, have high dry residues (UV). The outcome? High-efficiency lines that retrieve all unused product, allow fast colour changeovers and employ semi-automatic roller cleaning systems that have the further advantage of containing running costs.
Overhead and floor-mounted lines are perfect for managing production batches that require limited worker intervention. They’re also well suited to small orders, which involve frequent changes to colours and processes. All this stems from simplified programming of the coating machines, which feature tools that constantly monitor coating delivery. This prevents waste and reduces the rejection rate among products leaving the line.
Lastly - again with a view to optimizing production processes - there’s the still little-explored area of industrial digital printing, ideal for customising products or handling extremely limited production runs.
Applying modern digital printing techniques to object decoration doesn’t just let manufacturers deliver products more quickly: it also reduces the need for stock, minimising warehousing requirements and streamlining supply chains.
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