New Powder Coating System for Sheet Metal Components

Contract manufacturing of sheet metal components places high demands on the coating process. A new automated powder coating system enables quick color changes, uniform coating thicknesses, and more efficient use of powder and energy.

Through targeted investments in modern manufacturing technologies, Greenfield Engineering continues to strengthen its position as one of the leading contract manufacturers of sheet metal components in the United Kingdom. With more than 7,432 m² of production space across two locations in Holsworthy in the southwest of England, the company offers solutions for precision sheet metal fabrication, powder coating, assembly, and integrated manufacturing. The industries it serves include, among others, furniture, lighting, laboratory equipment, transportation, electronic enclosures, and industrial engineering.

As industry requirements continue to evolve, Greenfield Engineering decided to thoroughly modernize a powder coating system that had been in reliable use for over 25 years. Increasing product complexity, higher customer expectations, and the company’s extensive investments in modern manufacturing technologies also made it clear that a solution was needed in the area of surface finishing that would meet the high standards of the entire operation. In collaboration with TD Finishing and Wagner, one of the most modern powder coating systems in the United Kingdom was thus created.

The powder coating project is part of a comprehensive investment program in Greenfield Engineering’s manufacturing processes. Recent initiatives include fiber laser cutting technologies, automated punching systems, robot-assisted bending solutions, state-of-the-art quality assurance equipment, renewable energy generation systems, and digital manufacturing systems. The goal was therefore clearly defined: to configure a powder coating system that enables the highest surface quality, excellent reproducibility, and high efficiency, while also supporting future growth.

Frank Green, founder of Greenfield Engineering, explains: “Our customers expect consistently high standards. It was important to us to create a process that always delivers the same high-quality finish, regardless of the operator’s experience. This investment sets the standard for the future of our coating processes.” Together with TD Finishing and Wagner, Greenfield modernized the entire line. This includes a fully automated five-stage pretreatment process, state-of-the-art drying and curing ovens, new conveyor systems, an intelligent powder recovery system, and cutting-edge application technology. Installation was completed at the end of 2025, and production began in January 2026.

Choosing the right technology partner was a crucial part of the project. After a detailed evaluation of available systems, Greenfield Engineering opted for the latest generation of the Wagner IPS coating center—complemented by Wagner’s strong presence in the United Kingdom and its comprehensive after-sales service.

Daniel Green, Director at Greenfield Engineering, says: “This project wasn’t simply about replacing equipment. It was about creating a future-proof coating solution that meets growing customer demands, more complex product lines, and our long-term growth plans. Wagner’s market presence in the UK, the IPS’s performance capabilities, and strong after-sales support made this solution the obvious choice.” The installation includes the Wagner S-Line, an automatic powder coating system featuring S-Cube booth technology. It was specifically developed for companies with diverse production lines where flexibility and efficiency are equally critical.

A key requirement from Greenfield Engineering was the reliable execution of frequent color changes while maintaining consistent productivity and coating quality. Since more than ten color changes occur regularly per shift, minimizing downtime was particularly important. The self-cleaning S-Cube booth technology significantly reduces cleaning times, thereby enabling quick color changes with stable airflow and consistent coating conditions. The system includes twelve automatic PEA-X1 powder coating guns as well as additional guns for coating the undersides, ensuring that even larger and more complex components are reliably coated. For challenging geometries and special requirements, a manual coating station equipped with a Wagner Sprint 2 Expert is available. Together, these technologies ensure that Greenfield can combine outstanding coating quality with efficient material flow across a very broad product range.

At the heart of the system is Wagner’s advanced 3D coating technology. It automatically captures the workpiece geometry as it enters the booth and adjusts both the spray gun positioning to the spray distances and the powder feed to the gaps between the components. Especially in a high-variety production environment like that at Greenfield Engineering, this technology ensures uniform coating thickness across a wide range of geometries, reduces overspray, and minimizes waste.

A key feature of the installation is the IPS Coating Center—the first system of its kind in the United Kingdom. The platform combines powder preparation, conveying, dosing, and color changes into a single integrated system. Intelligent sensors continuously monitor powder output, weight, pressure, and fill levels, ensuring optimal conditions during production. Smart Feeding Technology ensures a stable powder feed rate even during long production runs, reduces process fluctuations, and improves consistency. For Greenfield Engineering, this represents a significant advance in process reliability and repeatability. Frank Green explains: “With our new system, we see that the standard is set by the system—not by the operator. We are now achieving a level of consistency that was previously impossible.”

Sustainability played a central role in the design of the new powder coating system. Wagner’s Energy Efficiency Package (EEP) combines an optimized monocyclone recovery system with state-of-the-art filter technology to reduce energy consumption while improving powder recovery. The optimized airflow design reduces pressure losses throughout the system, helping to lower operating costs and minimize environmental impact. At the same time, efficient powder management and high recovery rates improve material utilization and reduce waste. These benefits align with Greenfield Engineering’s overarching sustainability strategy, which includes, among other things, investments in solar power generation, waste prevention, and internationally recognized environmental management systems.

Since the system went online, Greenfield Engineering has seen significant improvements in several areas of the coating process. Key benefits include: greater coating consistency and repeatability, improved surface quality for complex product lines, lower powder consumption and less overspray, greater process control and transparency, higher productivity through faster color changes, less reliance on individual operators, and a reduced environmental impact thanks to improved energy efficiency and recovery. Managing Director Gary Burnard comments: “It’s a win-win situation. We’re increasing our productivity while simultaneously reducing waste and supporting our environmental goals. The system’s performance has exceeded our expectations.”

The project’s success has reinforced Greenfield Engineering’s commitment to continuing to invest in modern manufacturing technologies. As customer requirements are constantly evolving, the company is focused on expanding its capabilities, increasing the level of automation, and further improving quality, efficiency, and sustainability across all areas.

Gary Burnard summarizes: “The results of this investment give us the confidence to continue investing in the future. Our goal remains to deliver world-class manufacturing solutions and create long-term value for our customers.” For Frank Green, the project represents an important milestone in the company’s development: “The investment has fundamentally transformed our coating capabilities. The consistency, appearance, and overall quality of the coated products have exceeded our expectations and further strengthened our performance for our customers. Our powder coating has thus reached a new level.” (OM-8/26)