Revamping (from the English verb “to revamp,” meaning “to renew” or “to restructure”) is a technical and technological upgrade of existing systems. In the case of coating plants, revamping involves modifying, replacing, or integrating components or systems to restore or improve performance, efficiency, safety, regulatory compliance, finished product quality, and/or environmental sustainability, without the need to build a new plant.

Revamping may include:

  • replacement of obsolete machinery (washing tunnels, baking or drying ovens, etc.);
  • updating handling, ventilation and heating systems;
  • renewing process controls (instrumentation, automation);
  • ensuring compliance with environmental, safety and emission control regulations, and/or improving energy efficiency.

Why is revamping important for coating plants?

There are many reasons why revamping a coating plant is a smart choice. Here are some of them.

Technological obsolescence

Over time, certain components become obsolete: they consume more energy, produce defects, lack precise parameter control, and have hard-to-find spare parts. Revamping allows the integration of more modern, precise, and reliable technologies, improving the overall quality of the painting process.

Environmental and safety regulations

Regulations on air emissions, wastewater management, operator safety, and energy efficiency are constantly evolving. An outdated coating plant may no longer comply with the latest standards. Revamping provides the opportunity to meet current regulations without building a new facility from scratch.

Energy efficiency and operating cost savings

Newer technologies, better insulation, heat recovery systems, optimized airflow and ventilation, and modern control systems help reduce energy consumption and operational costs.

Extending the plant’s useful life

A well-maintained and updated industrial system can continue to operate effectively for many years beyond its original lifespan. This helps avoid the significant expense of investing in a completely new facility.

 What are the benefits of revamping?

Here is a detailed overview of the key benefits a company can achieve by investing in the revamping of its coating plant:

Advantage
 Technical Description
Improved finished product quality
 Greater uniformity of paint thickness, better finishes, and reduced errors such as runs, surface defects, and overspray. More controlled temperature, humidity, filtration, and ventilation systems.
Increased productivity
 Reduced cycle times thanks to more efficient ovens, faster handling, more flexible configurations, and automation or robotic systems.
Energy savings
 Ovens with improved insulation, heat recovery, more efficient motors or fans, optimized electricity consumption, efficient lighting, and reduced energy losses.
Reduced operating and maintenance costs
 More readily available spare parts, new components less prone to failure, less downtime, scheduled and predictive maintenance, and lower consumption of refrigerants or auxiliary systems.
Regulatory compliance
 Air emissions, waste management, VOC limits, workplace safety, health and safety regulations, upgrades to spray booths, filters, and purification systems.
Environmental benefits
 Lower environmental impact due to reduced energy consumption and waste, and improved management of residues, dust, and paint.
Production flexibility
 Ability to adapt the system to new paint types, new cycles (liquid, powder, UV), vary production volumes, modify internal layouts, and adjust capacity.
Lower costs
 Compared to investing in a completely new system, revamping typically requires less capital and offers a shorter payback period.

What are the typical technical interventions in a project of a coating plant revamp?

Here are the technical interventions that companies like Verona Impianti can perform when carrying out a revamp:

  • Initial diagnosis: assessment of system condition, technical measurements, testing, evaluation of components subject to wear or inefficiency, and analysis of available space.
  • Replacement or upgrade of drying/baking/polymerization ovens: installation of more thermally efficient equipment or conversion from fossil fuels to electric power systems.
  • Renovation of paint booths: improvements to filtration, ventilation, overspray capture, safety, and operator comfort systems.
  • Modernization of handling lines.
  • Upgrade of automation and process control: sensors, PLCs, temperature and humidity regulation, airflow management, monitoring, and supervision software.
  • Structural improvements: thermal insulation, cladding, doors, and locking systems.
  • Energy optimization: heat recovery, use of high-efficiency burners, LED lighting, and energy management systems.
  • Environmental and safety compliance: emission abatement systems, VOC control, safety devices, PPE, barriers or shielding, signage, and risk assessment.
  • Improvement of ergonomics and working conditions: indoor air quality, noise reduction, temperature and lighting optimization, ease of access, and workstation safety.

Phases of the revamping process

Revamping is not an improvised operation, because it requires careful planning and clearly defined phases:

  1. Preliminary analysis and technical survey
    Inspection, assessment of current performance, identification of weak points, and estimation of operating costs, energy consumption, emissions, and product defects.
  2. Project planning
    Definition of objectives (consumption reduction, improved quality, compliance, etc.), selection of technologies to integrate, layout design, supplier selection, cost estimation, downtime planning, and ROI (Return on Investment) assessment.
  3. Budgeting and financial planning
    Economic evaluation of the investment, payback time estimation, potential tax incentives or environmental grants, and budgeting for future maintenance.
  4. Execution of works
    Installation of new components, structural modifications, integration of control systems, system upgrades, testing, calibration, and inspections.
  5. Commissioning and verification
    Production start-up, monitoring of critical parameters, defect detection, and fine-tuning of the process.
  6. Post-intervention maintenance and periodic updates
    Routine and extraordinary maintenance, performance analysis, and verification of ongoing regulatory compliance.

How Verona Impianti approaches revamping

Revamping coating plants is not just a way to “renew” an old system, but it is a strategic approach that can deliver tangible benefits, including improved finished product quality, higher operational efficiency, energy savings, regulatory compliance, and enhanced market competitiveness.

For companies aiming to stay up-to-date with technological and regulatory developments, considering a revamp is an essential step. It requires careful planning, a clear understanding of costs and benefits, and the selection of reliable partners with proven industry expertise.

At Verona Impianti, we have been active in the industrial painting sector for over 40 years, handling not only the design and installation of new systems but also modifications, revamping, and expansions of existing facilities. For more information on how to make your painting line more modern and efficient, contact us.