Coatmaster: New operating system for closed-loop coating thickness measurement

True closed-loop control in powder coating is only possible if the control is based on the actual coating thickness measured on the component - not on assumptions about the application efficiency. By measuring immediately after the coating process and integrating seamlessly into any system via Flex apps, the Coatmaster Flex enables the first robust, results-oriented control loop for industrial coating lines. A year ago, only three powder coating lines worldwide were equipped with a closed-loop solution based on Coatmaster technology. Today, over fifty-five production lines are already operating with automated, intelligent coating control - a clear sign that the industry is ready for the next generation of process optimization.

Keeping coating thickness constant automatically and in real time

Coatmaster partners and customers kept asking: "We want a true closed-loop system - one that keeps the coating thickness constant automatically and in real time." Coatmaster FlexOS V7 makes this vision a reality. The new operating system combines non-contact coating thickness measurement, advanced connectivity and integrated AI tools to make result-oriented coating control accessible for every production line. Coating efficiency is never constant - it changes due to gun parameters, electrostatic effects, geometry and environmental conditions. Control before the coating process, for example directly at the gun, cannot compensate for these fluctuations. Only a measurement of the coating thickness immediately after the coating application provides a reliable basis for process control. By using this measurement as a control variable, the coating line can automatically adapt to changing conditions and keep the coating thickness stable - regardless of external influences.

New generation of powder coating control

FlexOS V7 introduces Flex-Apps - modular, customizable software modules that run directly on the Coatmaster Flex. They enable system manufacturers and end users to develop their own control algorithms, seamlessly connect to any PLC or fieldbus interface and automatically adjust the powder output in real time. In combination with integrated AI analytics, the system continuously learns from process data and supports predictive, adaptive optimization - for consistent quality, reduced material consumption and maximum process stability. Prof. Dr. Nils Reinke, Co-Founder and Co-Sales Director of Coatmaster AG, explains: "With OS V7, we are not just launching a new version - we are creating a platform that enables our customers and partners to integrate intelligence, connectivity and automation directly into their coating lines. By making closed-loop control and AI-powered optimization standard, we are opening up new possibilities - and empowering our distributors and integrators worldwide to not just measure, but truly master coating processes." Coatmaster FlexOS V7 will be available from November 30, 2025. Existing Coatmaster Flex systems can be upgraded to the new version via a software update, giving them access to all the new features, including Flex apps for closed-loop and AI support.