Automated powder coating line in the modernization project of the Sami Valga factory

Project challenge

The company's production units were previously located in Saue, Otepää and Valga, but in order to streamline production, it was decided to close the Otepää factory and consolidate production in Valga. The previous coating line was the "bottleneck" of production, as it did not allow the coating of large-dimensional products, which limited production volume and efficiency. The choice in favor of powder coating also stemmed from the demand of customers, especially Finnish clients, for powder-coated products.

How we built the solution

We built a 4000 m² new construction and an equally large reconstructed area, which made it possible to integrate production solutions with the latest technologies. The installed automatic powder coating line enables the pre-washing and coating of large and complex products as well as more economical and environmentally friendly production. Compared to wet coating, powder coating provides a stronger and more durable surface coating, does not release solvent vapors or hazardous compounds, and uses reusable paint.

Advantages of powder coating:

• Higher quality result – stronger and more durable surface coating
• Environmental friendliness – no solvent vapors or hazardous compounds are released
• Lower paint consumption – powder paint is reusable

Result

The new coating line eliminated the production bottleneck and made it possible to optimize the production process and increase efficiency. The system significantly reduces environmental impact, as the residual heat from the coating line oven is directed to heating the production building and welding halls.

Results achieved:

• Significant energy savings
• Cleaner production – clean air ensured through good ventilation and the elimination of solvents
• More efficient paint usage – overspray powder paint circulates until reuse, and only cured powder is sent to waste
• This is already the third coating line installed at Sami's factories

Broader cooperation in modernizing Sami's production

Our contribution was not limited to installing the coating line only – we have also helped Sami Tootmine in the development of welding ventilation, robotic welding and manual welding workstations both in Valga and in Saue.

Key projects:

• One of Estonia's largest complete welding ventilation systems at the Saue factory – 30 manual welding stations and 7 welding robots
• Ventilation systems taking into account the number of employees to ensure better air quality and to ventilate the industrial building
• Three coating lines at Sami's factories