Saving paint on door and gate systems thanks to electrostatic guns

The painting process for technically sophisticated door and gate systems was converted to electrostatic technology. This reduced paint consumption by 30 percent and led to a significant reduction in VOCs.

By switching to modern electrostatic technology, Hodapp has optimized the painting process together with engineering partner Oltrogge - with impressive results: 30 percent less paint consumption, significant VOC reduction and even more reliable corrosion protection. The environment, operational efficiency and product quality benefit noticeably from this.

Hodapp GmbH & Co KG, based in Achern-Großweier, is a specialist in technically sophisticated door and gate systems made of steel, stainless steel and aluminum. The company's range of services extends from development and production to the installation of customized solutions. The company's high-quality heavy-duty and security doors are used in security-critical areas such as railroad facilities, prisons, tunnels and data centers. The highest standards of protection, durability and functionality apply here. Reliable corrosion protection is therefore essential.

Since its foundation in 1946, Hodapp has not only been driving forward pioneering new developments, but also continuously optimizing existing systems and processes. The most recent goal: converting the painting process in order to sustainably improve the environmental balance. "We wanted to reduce paint consumption by at least 15 percent in order to significantly reduce VOC emissions from solvent-based coatings when painting our doors and gates. At the same time, we wanted to reduce overspray without changing the current painting speed," says Markus Lang, Production Manager at Hodapp GmbH & Co. KG, explaining the objectives at the start of the project in July 2024. "It was important to us that the surface quality and therefore the corrosion protection remain high. That's why we turned to the surface specialists from Oltrogge in Bielefeld, who we first met at PaintExpo 2024 in Karlsruhe, for the implementation."

In order to achieve the desired goals, the Oltrogge team developed a clearly structured process plan. First, the conductivity of the master lacquer was checked in order to determine the technical requirements and explore the possibilities of electrostatic coating. This was followed by the selection of the optimum application technology - from manufacturer to nozzle to pressure - precisely tailored to Hodapp's production. "We didn't want a theoretical solution. It was important to us that we test directly on Hodapp's doors and gates," recalls Frank Eckert, Area Sales Manager at Oltrogge GmbH & Co. "This test phase enabled us to analyze the initial results and adjust the parameters in a targeted manner." Hodapp particularly remembers the practical electrostatic tests directly at the plant, which made the "wow effect" in terms of savings and increased efficiency immediately tangible. "That was the moment when we all knew: this works - and better than we thought," says Markus Lang.

After the test phase and extensive consultation with Frank Eckert, Area Sales Manager at Oltrogge, and Burkhardt Gärtner from Oltrogge partner Binks, the decision was easy for Hodapp: the painting process was switched to two electrostatic spray guns from Ransburg's Vector series. Their low weight, easy handling and optimized electrostatic technology significantly increase application efficiency and reduce material consumption and VOC emissions - ideal for sustainable work with consistently high surface quality. In addition, respiratory protection technology from Sundström ensures maximum work safety at Hodapp.

The results are impressive: paint consumption at Hodapp has been reduced by 30 percent; VOC emissions have fallen by the same amount. In addition, the cleaning intervals of the paint booth were extended, reducing downtime and maintenance costs. Quality, coating thickness and surface appearance remained constant, while less overspray ensured clean working areas and faster painting times. The surfaces are now smoother, more uniform and visually superior. In addition, the optimized coating process ensures even more reliable corrosion protection - for a significantly longer service life of the doors and gates. Production Manager Markus Lang is delighted with the result of the collaboration: "With the new electrostatic technology, we not only save 30 percent on paint, but also ensure the long-term corrosion protection of our products - more efficiently, cleanly and sustainably than ever before." (OM-4/26)