News Best Practice
Greenfield Engineering installs future proof powder coating line
The British sheet metal contract manufacturer has replaced a coating line that had been in service for more than 25 years, introducing automated application technology and integrated powder management at its Holsworthy site.
The UK contract sheet metal manufacturer has replaced a 25-year-old finishing line with an automated powder coating installation, delivered in partnership with TD Finishing and Wagner.
Greenfield Engineering, which operates from more than 7,400 m² of production space across two sites in Holsworthy in South West England, has completed a full modernisation of its powder coating operation. The company supplies precision sheet metal fabrication, powder coating, assembly and integrated manufacturing services to customers in furniture, lighting, laboratory equipment, transport, electronic enclosures and industrial technology.
Replacement of 25 year old powder coating line
The previous powder coating plant had been in service for more than 25 years. Increasing product complexity, evolving customer requirements and wider investment in advanced manufacturing technologies across the business led the company to develop a finishing facility aligned with the standards applied elsewhere in its operations. Installation was completed in late 2025, with production commencing in January 2026.
The project forms part of a broader investment programme that has also included fibre laser cutting, automated punching, robotic bending, quality assurance equipment, renewable energy generation and digital manufacturing systems. The finishing line now incorporates a fully automated five-stage pre-treatment process, drying and curing ovens, new conveyor systems, powder recovery technology and updated application equipment.
Creating a future-proof finishing operation
Frank Green, founder of Greenfield Engineering, said: “Our customers expect consistently high standards. We wanted a process that delivered the same high-quality finish every time, regardless of operator experience. This investment establishes the benchmark for the future of our finishing operations.”
Following a review of available systems, the company selected Wagner’s IPS powder application technology. Director Daniel Green commented: “This project was not simply about replacing equipment. It was about creating a future-proof finishing operation capable of supporting increasing customer expectations, greater product complexity, and our long-term growth plans.”
For particularly complex geometries, the line includes a double manual coating station. (Picture: Wagner)
Faster colour changes
A central requirement was the ability to manage frequent colour changes without compromising throughput. With more than ten colour changes typically occurring during a shift, the self-cleaning booth technology reduces cleaning times between colours while maintaining stable airflow conditions. The system uses twelve automatic powder guns alongside dedicated guns for underside coating, complemented by a manual coating station equipped with controllers for intricate geometries and specialist finishing tasks.
The installation includes 3D coating technology. Each component entering the booth is scanned, allowing the system to identify workpiece geometry in real time. Automatic gun positioning continuously adjusts spray distances to optimise coverage and powder utilisation without manual programming. The system also recognises gaps between components and disables powder delivery when no product is present, reducing consumption.
First UK installation of the powder centre
A significant feature of the project is the powder centre, the first system of its type installed in the United Kingdom. It combines powder feeding, conditioning, sieving and colour change management within a single integrated platform. Sensors monitor powder flow, weight, pressure and fill levels, while smart feeding technology maintains a stable transfer rate during extended production runs.
Frank Green noted: “We’re finding with our new system that the standard is set by the system, not by the operator. We’re now achieving a level of consistency that simply wasn’t possible before.”
Sustainability considerations informed the design of the facility. An energy efficiency package combining an optimised mono-cyclone recovery system with advanced filtration reduces energy consumption and improves powder recovery. The airflow design lowers pressure losses across the system, contributing to reduced operating costs. These measures complement the company’s wider sustainability strategy, which includes on-site solar generation, waste reduction initiatives and certified environmental management systems.
The final filter operates with a smaller fan motor thanks to WAGNER’s Energy Efficiency Package. (Picture: Wagner)
Improved powder coating operation
Since commissioning, the company reports improvements in coating consistency and repeatability, finish quality across complex product ranges, reduced powder waste and overspray, greater process visibility, faster colour changes, reduced operator dependency and lower energy consumption.
Managing Director Gary Burnard said: “It’s a win-win situation. We’re achieving improvements in productivity while simultaneously reducing waste and supporting our environmental objectives. The performance of the installation has exceeded expectations.”
Frank Green added: “The investment has transformed our finishing capability. The consistency, appearance and overall quality of the coated product have exceeded expectations and further strengthened the service we provide to our customers.”
More information: www.wagner-group.com, www.greenfieldengineering.co.uk