The Production Equipment Market

Sustainability is an important topic in industry today, and paint and coatings are no exception. Choosing the right production equipment is as critical as selecting the right ingredients, and equipment suppliers are developing new products that enhance sustainability.

WAB US Corp. president Daniel Grskovic reported that the second half of 2024 was better than the first.

“Speculation included uncertainties in the political climate earlier in the year and impact on domestic interest rates on home and automotive loans that reflected output,” he said. “When the housing and automotive sector is turbulent, there’s a clear impact to paint production and equipment purchases. Boeing had a rough year and that ripples through aerospace paints and
coatings production.”

Grskovic pointed out that the priority is always productivity output gained through more efficient process technology.

“But we can also exceed the expectations on product quality, energy consumption, waste management, and operational costs (including easier maintenance with faster changeovers) with our latest equipment,” added Grskovic. “It’s not just about producing more even though that seems to be the main focus. The customer needs to understand a clear path to new machine ROI to justify capital expenditures. We’re able to ‘do the math’ to show the ‘total value’ of investment in new equipment and there’s a lot of additional value in areas other than just output.”

“With a push towards greener and more sustainable products, many of our customers in the paints and coating space were looking at ways to optimize their formulations and production efficiency while shifting their ingredients to eliminate PFAS and other harmful compounds,” said Erin Dillon, media and marketing coordinator for ROSS.

Dillon noted that when manufacturers update their formulas without PFAS, often times their existing mixing equipment isn’t ideal for the new ingredients, as these raw materials have different physical characteristics that require more advanced equipment.

“That’s why our Test & Development Center has become such a valuable resource,” Dillon added. “We invite customers to bring their own raw materials and run proof-of-concept demonstrations with our full range of mixing equipment. Their technical and R&D personnel can get hands-on experience with the equipment before making a purchasing decision. This practical, try-before-you-buy approach has been invaluable for our customers.”

Sara Fulford, VP sales & marketing for Hockmeyer Equipment, said that paint and coatings manufacturers are selecting options that align not only with their production goals, but also with their sustainability initiatives.

“Coatings manufacturers are increasingly focused on improving production efficiencies to meet growing market demands,” Fulford noted. “As a result, we have observed a significant rise in projects that require equipment capable of handling very large batch sizes, and also, projects that emphasize the need for advanced control options that incorporate sophisticated data-gathering capabilities, allowing for better monitoring and analysis of the production process. These systems allow manufacturers to monitor operations in real-time, offering insights that enhance decision-making and boost overall productivity.”

Fulford also observed that the importance of safety cannot be overstated.

“Manufacturers are placing a premium on integrating enhanced safety features into their equipment to protect employees and comply with stringent industry regulations,” she said. “This concerted effort toward efficiency, data-driven insights, and robust safety measures highlights a pivotal shift in the coatings industry, as companies adapt to meet both the challenges and opportunities of modern production demands.”

“With the help of Buhler and our upgrade or retrofit options, customers are utilizing existing production equipment where possible or choosing to implement the newest, high efficiency solutions for process improvements,” Patrik Maeder, senior sales director at Bühler Group, said.

Greg Shrider, VP, head of global key accounts for BYK-Gardner, noted that quality control equipment continued to be relevant in 2024 in the paint and coatings sector.

“Overall, year over year equipment sales were flat as well as the number of locations served,’ Shrider added. “This aligns with overall production growing at a slow rate. While the investments in new sites is seeing growth in 2024, those sites are yet to be completely outfitted which is promising for 2025. We saw an increase in the industrial application sector in quality control equipment. Leading the increases were the automotive, aerospace and coil coating applications.”

Shrider pointed out that upgrading and replacement purchases are two different types of projects.

“Typically, we see manufacturers upgrade equipment when a repair is too costly compared to purchasing new equipment,” he added. “This could be because the equipment has some type of computer interface and replacement boards or other electrical repair is perceived to be too high compared to purchasing new equipment. The key decision is usually that the equipment is well beyond the payback period and new features and/or better performance justify an upgrade.

“Replacement purchases are usually justified because a piece of equipment or testing device becomes damaged and the results generated fail a specification,” Shrider continued. “In these cases, it is easy to justify purchasing a new device because the product needs to pass specification.”

Sustainability and Equipment

There is a lot of interest in sustainability, and equipment manufacturers can help in that regard.

Grskovic noted that machines that are designed to operate efficiently and conserve resources align with sustainability goals by reducing operational waste and environmental impact.

“Sustainability considerations have become a key contributor in the decision-making process for machine purchases,” Grskovic added. “We are uniquely able to offer the customer process technology in a smaller footprint than before while producing more efficiently and decreasing waste significantly. Having a newer smaller machine that can outclass an older, much larger machine in every way possible means less waste, lower energy costs, and less downtime. These are all pro-sustainability.”

Dillon noted that sustainability encompasses the entire production process, including equipment longevity.

“ROSS Mixers are built to last, with machines still operating on customer production floors after decades of use,” Dillon added. “Additionally, our buyback and refurbishment program ensures equipment is reused, reducing waste and contributing to sustainable practices.”

Fulford noted that Hockmeyer Equipment is dedicated to support its customers by focusing new developments on equipment that aligns with their needs: streamlines processes, eliminates bottlenecks, prioritizes operator safety and utilizes the latest data collection technology for well-informed decision-making.

“Furthermore, we offer our clients the unique opportunity to trial our advanced technologies, allowing them to explore various machine configurations tailored to their specific applications,” Fulford added. “This hands-on experience not only aids in identifying the best fit for their needs but also serves to build confidence in their purchasing decisions by demonstrating the tangible value and performance of our equipment.”

Maeder noted that customers are seeking higher productivity, reduced footprint, increased equipment safety, and automated equipment or processes.

“Bühler is committed to helping our customers achieve their sustainability goals through innovative design, advanced engineering solutions, and stringent manufacturing practices,” Maeder noted.

“New equipment or technology saves producers time and money by increasing productivity through innovative design and the use of high-efficiency materials,” Maeder said. “Automation and reduced footprint streamline operations, while supportive services enhance performance. These advancements result in a higher production ratio ($/lbs), ultimately driving cost-effectiveness and operational efficiency.”

When it comes to sustainability, Shrider said that customers are focused on maintenance and certification when looking at new equipment purchases.

“Our experience is that a new purchase will have a payback period of months or one to two years while the life of the equipment will be 10-15 years minimum depending on the process and piece of equipment/instrumentation. If there is software that is used with the equipment/instrumentation, then compatibility with IT requirements is a necessity,” said Shrider.

“We also have seen increased interest in robotic solutions. While hiring skilled labor is always in the conversation, improving quality and the desire to acquire more measurements is the key driver.”

New Products

Leading production equipment manufacturers have introduced new products to help customers meet their goals. Hockmeyer has launched its HRX and HIPS (Hockmeyer Integrated Process System) product lines. HRX is designed for products that require a temperature-regulated environment during processing, while HIPS connects the system’s software and hardware.

Dillon noted that ROSS has developed some new advances, such as the ROSS X-Series.

“The ROSS X-Series is a newer generation rotor/stator technology which fills the gap between standard high shear mixers and traditional milling equipment,” said Dillon. Turning at tip speeds over 11,000 ft/min, the X-Series rotor consists of concentric rows of intermeshing teeth. The combination of high tip speed and extremely close tolerances between the interlocking channels subjects the ink to intense shear in every pass.

“This ultra-high shear mixer routinely produces fine pigment dispersions superior to those made in single- and multi-stage rotor/stators, as well as colloid mills. An alternative technology worth considering for high-throughput requirements, the X-Series is much easier to clean and maintain compared to most mills used in the ink and coatings space,” Dillon added.

Driven by end-user demand, Shrider said that BYK-Gardner has integrated PELT multi-layer film thickness measurement capability into its smart-chart quality control software. This allows users to track film build along with multi-angle color measurements as well as appearance measurements, ultimately allowing for quicker reaction time to any issues that would impact color match and appearance specifications, color harmony and process issues impacting film build of any of the layers of painted product.

The new CV3evo dissolver, manufactured by VMA Getzmann, has a new compact design with higher functionality such as a closed worktop, unique lifting column, integrated control panel, large color display with light-up buttons and system adaptability. The CV3evo has optional modular components for more flexibility to accommodate future growth and scaling up of processes from R&D to production.

“As a private company, the focus on maximizing resources into continuous research and development in machine design has allowed us to create proprietary process technology that takes paints and coatings production a step further,” Grskovic noted. “This has resulted in wet bead milling system designs (like in our latest Universal Bead Mill or UBM technology) that improve the pigment strength and glossiness of the product as well. Reducing materials cost is a huge win for the customer that gives them a competitive edge in the market as a result.

“In addition, we have also released our IMPA°CT REACTOR, WAB’s latest innovation in the field of mechanochemistry,” Grskovic added. “An inductive heater arranged around the stirring elements enables direct and efficient heating of the reactants up to +160 °C. Together with the impact beads located in the reactor chamber, the WAB IMPA°CT REACTOR is a ground-breaking, user friendly and application-specific apparatus for molecular synthesis by means of mechanochemistry. Conventional batch processes can be replaced by a continuous process. The newly developed WAB IMPA°CT REACTOR enables faster, more selective and novel reactivities. Industrial scale-up from g/h to tons/h is also available.”

“Whether or not a customer is ready to purchase new equipment or just wants to improve their current process, WAB offers trials through our Process Technology Center or PTC in Allendale, NJ,” Grskovic noted. “I like to refer to it as our ‘proving grounds’ enabling us to show customers what our process technology can do for them. Customers can easily scale up lab mill results to pilot size then production size all within our company headquarters in real time. The PTC experience helps the customer make the best investment decision for their unique needs and budget if they’re in the market for something new or helps them tweak their current process to optimize to the highest level possible.”