Ready to Build Your Coating Line? Design a High-Efficiency Painting Line Tailored to Your Product.

— Bigtoyo Machinery

When companies plan a new coating production line, the first step is often to ask for quotes. But spray coating systems are not standard products you can just buy off the shelf. A truly effective solution depends on understanding your product's specific features, the type of coating you'll use, your desired output, available factory space, and your budget. Without clearly defined needs, you risk getting inaccurate quotes—or worse, investing in a line that underperforms, overruns your budget, or fails to go into operation at all.

So, before you start buying anything, take a step back. Understanding what your product needs and how your whole process works is the foundation of a successful coating line. In this article, we walk through several key factors that influence how a spray coating system should be designed — and what you should clarify before making any decisions.

Structure

1. Product Geometry: The Starting Point of System Design
2. Material and Surface Preparation: A Critical Pretreatment Process
3. Size and Weight: Key Factors for Conveyor Design
4. Process Flow and Line Speed: Every Step Matters
5. Coating Type and Drying Method: Different Paints, Different Solutions
6. Capacity and Automation: Automation Isn’t Always Better
7. Facility Constraints: Space, Utilities, and Infrastructure
8. Staffing and Maintenance: Sustainable Operation Matters
9. Conclusion: The Best Coating Line Starts with the Right Questions

1. Product Geometry: The Starting Point of System Design

The appearance of your product is the main thing that decides how your coating line will be designed. Customers come from all industries — from electronics and cosmetics to automotive parts, steel structures, and furniture. 

Flat, panel-like products such as cabinet doors or tabletops are typically use reciprocating spray machines combined with rollers or conveyor belts to ensure even, high-speed coverage. Big Toyo’s flat spray coaters (e.g., auto cleaning painting machine for pallet, automatic painting machine with multi-layer oven) are specifically designed for these types of products.

For products with more complex shapes – like round pipes, molded parts, or odd-shaped covers – spraying from multiple angles is necessary. This might involve robot arms, rotating tables, or custom-built systems to cover all surfaces. For example, we've designed pipe coating lines and ceramic molding spray systems, all made specifically for our clients' unique needs.

2. Material and Surface Preparation: A Critical Pretreatment Process

What your product is made of directly affects how well paint sticks and how it dries. For example, wood or MDF (used in furniture) needs a sealing primer and careful control of moisture. Metals, on the other hand, usually need degreasing, rust removal, and drying before painting. This makes sure the paint sticks well and prevents rust. For plastics like ABS, PP, or PC, which don't hold paint well on their own, a flame or plasma surface treatment is highly recommended to help the paint stick better.

It's easy to overlook, but proper pre-treatment greatly impacts the line's layout, how much energy it uses, and which equipment you choose. So, it’s best to consider it early in the planning process.

3. Size and Weight: Key Factors for Conveyor Design

Your product's size and weight are very important for choosing the right conveyor system. Small parts, for instance, can be moved efficiently using spinning trays or hooks. Medium to large panels, however, often need belt or roller conveyor platforms. For long workpieces, an overhead conveyor system might be the best, while very heavy items may require a towcart conveyor system.

Each way has different needs for support, production speed, and space. So, it's very important to evaluate these details early when planning your line.

4. Process Flow and Line Speed: Every Step Matters

Rather than jumping directly to the spray booth, a complete line includes loading, coating, drying, cooling, and unloading. Each step impacts the line’s speed and layout — neglecting any stage can lead to bottlenecks or inefficiencies.

For example, a typical wood product workflow might include loading → staining → base coat → drying → cooling → sanding → topcoat → final drying → cooling → and unloading. For metal parts, pretreatment steps such as hot water rinsing, detergent cleaning, or drying are often required before electrostatic, powder or UV coating.

5. Coating Type and Drying Method: Different Paints, Different Solutions

Different types of paint require different drying approaches. Common drying methods include air drying (at room temperature), heated air drying, IR and UV curing— each with its own equipment and process considerations.

For example, Solvent-based paints dry quickly but require strict ventilation and VOC controls. Water-based paints, on the other hand, are eco-friendlier but more sensitive to temperature and humidity. They often need extra heated air or infrared (IR) drying equipment to speed up the drying process. UV coatings require controlled light exposure and precise curing parameters.

Factors like coating thickness, substrate material, temperature control, and the presence of cooling zones all play a role. Collaboration with both equipment suppliers and paint manufacturers is critical to choosing the right solution.

6. Capacity and Automation: Automation Isn’t Always Better

The level of automation should match your output goals and product variety. If your volumes are high and specs consistent, full automation can cut labor and improve efficiency. But for smaller batches or varied product lines, semi-automation may offer more flexibility and lower complexity.

Modular setups are also a smart option — start with core stations and leave room to scale.

7. Facility Constraints: Space, Utilities, and Infrastructure

Plant size, ceiling height, airflow, power, and other physical limitations can significantly affect system design. Energy sources like electricity, natural gas, or compressed air need to be assessed. If your facility has cleanroom standards or temperature/humidity control, these requirements must also be integrated into your layout plans.

8. Staffing and Maintenance: Sustainable Operation Matters

An advanced coating line is only valuable if your team can operate and maintain it. Consider how many skilled workers will be required, what preventive maintenance the system needs, and whether the supplier offers remote support or fast service when things go wrong.

Proactive planning here helps avoid downtime later.

Conclusion: The Best Coating Line Starts with the Right Questions

There’s no one-size-fits-all solution for coating systems. Every plant has different products, goals, and constraints. Instead of rushing to get a quote, take time to clarify your needs. Define your priorities, identify limitations, and set realistic goals. With this groundwork, your equipment partner can help you co-create the right solution — one that works not just on paper, but on your factory floor.

Need help getting started? At Big Toyo Machinery, we offer a Coating Line Planning Form to guide you through each step. Contact us — we’re here to help you build the coating system that fits your business best.