In VOMinfo: less energy, water and powder thanks to data and AI

In the theme issue of VOMinfo (05-2026), Tim Florizoone, managing director of ESTEE, explains how data-driven efficiency makes the consumption of a powder coating line visible and reduces it. And how AI makes that mountain of measurements usable for everyone.

A closed loop

Three flows largely determine the ecological footprint of a powder coating company: the heat from ovens and baths, the water and chemicals in the pretreatment, and the powder and compressed air in the booth. As long as these flows are only visible on the monthly invoice, saving remains a matter of estimation. Those who measure them per line section and per hour can intervene in a targeted way and validate the result objectively.

Data-driven efficiency follows a simple principle: measure everything, optimise where the data points, and measure the effect again. Modern lines combine the control of the conveyor system, pretreatment, ovens, booths and water treatment in a single automation platform for this purpose.

Ovens: using heat more intelligently

Measurements on an oven with a double-door system show a consumption of 377 kWh per hour during start-up, compared with 127 kWh per hour in steady-state operation. This immediately makes clear what an extra start-up or an unnecessarily long heating time costs, and what well-insulated vestibules deliver.

A second example is heat recovery from the curing oven to the drying oven. A comparison of gas meter data over two identical periods shows a saving of approximately 25% on the drying oven. With hybrid ovens that combine electric resistance heating and a gas-fired heat exchanger, the data also help to choose which energy source is the cheapest and least CO2-intensive at any given moment.

Pretreatment: water is energy too

In the pretreatment, water and energy consumption are closely linked, especially when wastewater is processed by evaporation. At 200 m² of treated surface per hour, switching from two to four cascade rinses saves 780 litres of water per hour. Because evaporating 1 m³ of water requires approximately 150 kWh, this means an energy saving of over 90,000 euros in the calculated case.

Continuous measurements of bath levels, conductivity and cascade flows also replace the uncontrolled natural cascade with controlled operation.

Powder and productivity

Inline film thickness measurement in a closed control loop prevents overcoating. At high volumes, powder consumption in kg per m² becomes a control parameter.

Productivity data also influence the footprint. On a continuous line, the conveyor chain speed turned out to be 20% lower, and the utilised hanging surface even 78% lower, than the theoretical potential. Every unused metre of conveyor chain increases the energy consumption per coated m².

AI makes data accessible

A modern line generates thousands of measurements every day. Artificial intelligence makes that mountain of data easier to use:

• AI models detect deviations in time series, such as an oven that stays at temperature unnecessarily long or a rising gas consumption per m², and help to trace the cause.
• Operators and production managers ask their questions in plain language and receive a substantiated answer, without having to wade through charts themselves.
• Machine vision recognises profiles automatically based on ERP orders, with human verification in case of doubt.

This shifts data analysis from specialist work to daily routine. At ESTEE, that is built into UNICoater, our own automation platform.

From insight to proof

Data make sustainability measurable and demonstrable, from a quality passport per product to preventive maintenance that prevents breakdowns and energy loss. This creates a self-reinforcing loop: the more a line measures, the more sustainable it becomes.

Source: „Minder energie, water en poeder dankzij data & AI“ (Less energy, water and powder thanks to data & AI), Tim Florizoone, VOMinfo 05-2026, pp. 20 and 21. Read the article in VOMinfo