Verona Impianti 2002, a company specialising in the design and manufacture of industrial painting systems, aims to ensure the complete satisfaction of its customers, even in the long term. A painting system is a complex machine that often operates under extreme conditions: high temperatures, dusty environments, humidity and aggressive chemicals. Without proper maintenance, even the most advanced system can gradually lose its efficiency.

This is why we strongly recommend regular maintenance, both routine and extraordinary, to ensure consistent performance, extended service life and maximum operational safety.

It is also important to assess, when purchasing a new painting system or equipment, how easy it will be to carry out maintenance operations, with the goal of simplifying and improving the aspects described below.

A well-maintained system allows you to:

  • Drastically reduce unscheduled downtime.
  • Optimise the consumption of paint, energy and compressed air.
  • Maintain consistent quality of the painted product.
  • Reduce operating costs and extend the system’s service life.

In this article, we will take a closer look at why comprehensive maintenance is so important, how to structure it effectively, and what the real risks of neglecting it are.

Why maintenance of painting systems is essential

Painting systems operate under challenging conditions and are constantly exposed to mechanical, thermal and chemical stress. During daily operations, dust from the working environment, paint mist and other residues tend to accumulate in ducts, filters, spray systems and automated mechanisms. This progressive build-up can compromise the correct functioning of the entire system, negatively impact the quality of the finish, increase the risk of unplanned downtime, endanger operator safety and cause waste that reduces the overall efficiency of the system.

Regular and well-structured maintenance, on the other hand, helps maintain high-quality painting standards, preventing visible defects and the need for rework. It also prevents unexpected breakdowns, supports production continuity and reduces the need for emergency repairs, which are often more costly. A properly maintained system consumes less, performs better and lasts longer. At the same time, it ensures a safer working environment for operators and helps the company comply with current safety and environmental regulations. In short, maintenance is not just a technical requirement but a strategic factor for the competitiveness and sustainability of the production process.

How to properly maintain painting systems

Maintenance should be seen as a planned investment rather than an incidental cost. It should be structured on two distinct levels:

  • Routine maintenance: recurring, low-complexity tasks that can be handled internally.
  • Extraordinary maintenance: more complex, specialised interventions to be carried out at scheduled intervals or when anomalies occur.

Routine maintenance: daily prevention

This includes all routine tasks aimed at preventing wear, build-up and minor anomalies that could develop into more serious issues over time. It should be performed daily, weekly or monthly, depending on the type of system and workload.

Regular cleaning of components

Painting booths, spray guns, air ducts and filters must be carefully cleaned to prevent the accumulation of dust, overspray and sticky materials that could compromise the uniformity of the coating and cause blockages.

Systematic cleaning helps to:

  • Reduce component wear.
  • Prevent anomalies in air flow or paint distribution.
  • Keep the work area clean, thereby improving safety.

Filter inspection and replacement

Air filters are essential to ensure a clean working environment and a finish free of impurities. Saturated filters reduce system efficiency by causing overpressure or insufficient suction.

It is necessary to:

  • Regularly check the condition of filters (visually or using instruments).
  • Replace them according to manufacturer specifications or production cycles.
  • Monitor the performance of the ventilation system.

Inspection of nozzles, pumps and painting equipment piping

Clogged nozzles or improperly calibrated pumps lead to uneven paint distribution, increasing material waste and the number of defective parts.

Recommended checks include:

  • Paint pressure and flow tests.
  • Visual inspection of nozzles and piping.
  • Preventive replacement of worn components.

Checking the efficiency of pretreatment systems

The water or water-based solution spraying systems used in pretreatment cycles must maintain their operational efficiency over time. So, it is recommended to regularly check for clogging and proper nozzle alignment to maximise their cleaning effectiveness.

Checking for proper air distribution in ovens

Air circulation ovens are the most commonly used for drying or curing of paint. By performing a simple visual inspection with the oven switched off, it is recommended to periodically verify that the internal air distribution slots are positioned according to the system’s calibration settings, i.e., arranged to ensure uniform temperature throughout the chamber. This helps make the paint curing process as consistent and even as possible.

Extraordinary maintenance: specialist and corrective interventions

This includes all technically complex operations requiring specialised equipment, professional expertise and often a controlled system shutdown. These interventions should be scheduled at regular intervals or triggered in case of malfunction.

Checking machine performance

The machines composing painting systems, especially if aged, should undergo performance checks such as:

  • Cleaning heat exchangers.
  • Checking temperature distribution and uniformity through thermal measurements using dedicated instruments (thermal cameras or GRANT devices).
  • Verifying atmospheric emissions.

Replacement of worn components

Over time, certain components subjected to repetitive cycles naturally deteriorate (spray nozzles, motors, valves, solenoid valves, components of overhead conveyors). If not replaced in time, they can cause cascading failures.

It is essential to:

  • Schedule inspections and replacements based on usage data.
  • Always use original or certified spare parts.
  • Document replacements to improve traceability.

Post-fault analysis and interventions

After a production stoppage or error report, it is crucial to perform a thorough technical diagnosis:

This requires:

  • Identifying the root cause (mechanical, electrical or software fault).
  • Conducting functional tests and validations after repairs.
  • Adjusting the maintenance plan to prevent recurrence of the issue.

What happens if you neglect maintenance

Postponing or ignoring maintenance can have serious consequences that impact the entire production process and the company’s bottom line. Even something as simple as a neglected filter can cause defects in hundreds of parts, unexpected downtime and gradual deterioration of the system.

The main risks include:

  • Poor paint quality: drips, lumps, bubbles, and surface impurities that lead to costly rework or scrapping of parts.
  • Unplanned production stoppages: sudden breakdowns causing delivery delays that damage the company’s reputation.
  • Higher repair costs: emergency repairs are more expensive than planned maintenance.
  • Operator safety hazards: malfunctioning equipment may expose operators to chemicals, mechanical failures or process errors.
  • Reduced equipment lifespan: accelerated wear leads to premature investment in replacements or major overhauls.

Verona Impianti 2002: by your side even after installation

At Verona Impianti 2002, we believe that the supply of a good system doesn’t end with design and installation. Real value is built over time by ensuring continuity, efficiency, and reliability at every stage of production.

That’s why we stand by our customers, providing comprehensive support even after delivery. We develop customised maintenance plans tailored to the company’s actual needs, considering working hours, production cycle types and technical equipment specifications. Our team of specialised, continuously trained technicians is ready to respond swiftly.

Additionally, we offer ongoing consultancy to help you prevent critical issues, optimise work cycles and consistently maintain top performance of your system.

If you want to enhance the efficiency of your painting line and have a reliable partner by your side, contact us today, we will be happy to help you create a maintenance plan perfectly suited to your needs.