Coating elevators efficiently with powder coating

An old powder coating system at an elevator manufacturer was replaced by a new system. The new system is energy-efficient and reduces powder consumption through automated measurement and control of powder output.

The Swedish company Motala Hissar is one of the leading manufacturers of space-saving elevators and platform lifts for indoor use. What began in 1972 with goods elevators has developed into an internationally active company: To date, more than 10,000 systems have been delivered and around 60% of production is exported. All mechanical components are manufactured at the Motala site in Sweden. Motala Hissar elevators stand for intelligent technology, clear Scandinavian design and a high level of user-friendliness. High-quality surfaces are an integral part of the quality promise - the coating process therefore plays a correspondingly central role.

Before the modernization, Motala Hissar was using an outdated powder coating system with a steel booth. High powder consumption, a low level of automation and time-consuming color changes were presenting the company with ever greater challenges. A new system was therefore needed that would coat the elevator components much more efficiently, reduce powder consumption and achieve fast, reliable colour changes. With the PXS powder center from Wagner in combination with Flowsense technology, the choice fell on one of the most modern automated solutions on the market. The new system was installed in summer 2025.

Motala Hissar opted for an S-Line powder system with an S-Cube cabin. This booth variant offers maximum flexibility and is designed for demanding applications with a high degree of automation - ideal for large-format elevator components. Eight PEA-X1 automatic guns ensure precise and even powder coating. The system is supplemented by a coating platform for manual pre- and post-processing of particularly complex components. The compact PXS powder center takes care of the complete powder preparation, supply and color change process. The entire system control is centrally integrated there. The Wicos control and operating system provides the user with a detailed overview of the system performance at all times. In addition, the PXS data hub interface provides raw process data for further production analyses.

The Flowsense technology integrated in the PXS measures and controls the powder quantity automatically: each conveying element is equipped with sensors that record the powder output in grams per minute. Deviations from the target value are corrected automatically. The result is constant coating thicknesses with reduced powder consumption. With Flowsense, Motala Hissar can now track exactly how much powder is actually being used. The constant layer thicknesses ensure consistently high quality. The effect is measurable: powder consumption has been reduced by 15-20% compared to the previous system. Another advantage is the predictive maintenance: the status of each injector is displayed on the touchscreen using a traffic light system. Replacement of wearing parts is only recommended when it is actually necessary. This significantly extends the service life of the capture nozzles and reduces operating costs. With the old system, the catcher nozzles had to be replaced every month - thanks to Flowsense, the system now runs for around 4 to 5 months without having to replace any wearing parts.

Like all Wagner powder systems, the new system at Motala Hissar is also equipped with the Energy Efficiency Package (EEP). The flow-optimized design of the monocyclone reduces pressure losses so that the secondary filter can be operated with a smaller fan motor. As a result, energy consumption has been reduced by 15-20%. The specially shaped pipes minimize powder deposits and wear and improve recovery. A small detail with a big long-term effect: the combination of Flowsense and EEP significantly reduces powder waste. As an average of 5-6% CO₂ emissions are avoided per kilogram of powder saved, this also has a positive effect on the environmental balance.

The new powder coating system at Motala Hissar combines speed, precision and sustainability at a level that could not be achieved with the previous solution. The coating of large workpieces and frequent color changes are now possible without any problems. The PXS powder center with Flowsense gives the production team full transparency of powder consumption and ensures reproducible high-quality surfaces. The energy efficiency package reduces energy consumption and increases recovery performance. With the new system, Motala Hissar can sustainably improve its productivity. (OM-2/26)