Automated Door Painting Line
Elister designed and installed a fully automated door coating line for Viljandi Aken ja Uks, where every step from loading to packaging is automated, traceable and data-driven. At the core of the solution are two CMA painting robots, RFID-based product identification, Graco dosing systems and a Power & Free conveyor that coordinates the simultaneous movement of up to **500 products**. The robot cycle time is **2 minutes** and every door produced has a digital passport.
Project challenge
For Elister OÜ, this was the first project of such scale where the entire responsibility — design, procurement coordination, logistics, and execution — rested fully on the shoulders of a single partner. The goal was to create a complete solution combining quality, speed, flexibility, and full traceability.
How we built the solution
We built a fully automated line where every step from loading to packaging is automated and data-driven. Two CMA robots operate independently, coating simultaneously with different shades and substances, while the entire product flow is coordinated by a Power & Free conveyor.
- Loading: vacuum lifters for safe hanging of doors
- Conveyor: Power & Free, coordinating the simultaneous movement of up to 500 products
- RFID product identification: each door with an RFID label, the system knows the product's location, colour, and recipe; separate low-frequency chips on the hanging booms to prevent signal interference
- Automatic cleaning: deionisation, compressed air cleaning, and aspiration, adapting to the dimensions of each door
- Paint kitchen: three Graco Duro-Flo base material pumps and Merkur series pumps for special shades; two special colour pumps per robot, cycle time 2 minutes
- Coating robots: two CMA robots; four Graco ProMix 3KS 3-component mixing systems (2 for the robots + 2 for the manual booths)
- Flash-off and drying: controlled solvent evaporation, a drying tunnel of up to +60 °C with air circulation of up to 60,000 m³/h and uniform cooling before packaging
Automation and remote management
The line is controlled by a system with four Siemens HMI control panels, a mobile tablet, cameras, and information screens, where every door produced has a digital passport. Safety is ensured by ATEX directive requirements, solvent, temperature, and humidity sensors in the control loop, and an STS fire detection system in the coating chambers.
Result
A fully automated door coating line has been completed, where every step from loading to packaging is automated, traceable, and data-driven. The solution combines quality, speed, flexibility, and full traceability in a single integrated production line.
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