This case study details the design, implementation, and performance of a fully automated flowcoat enameling system developed by Worldwide Finishing and Supply. The system was engineered to address key production limitations in a high-variability environment where large, welded heat exchanger assemblies required consistent, high-build porcelain enamel coatings.

The prior process—coating and firing each component individually before welding—was labor-intensive, tooling-dependent, and time-consuming. By enabling the entire heat exchanger to be coated and fired as a single part, the new system dramatically reduced cycle times and improved coating uniformity. Core challenges included managing shadowing across complex surfaces, ensuring precise enamel application with minimal waste, and delivering operational flexibility for varying product sizes.

The solution integrates a programmable rotator with modular tooling, actuator-driven nozzle arrays, and a closed-loop enamel delivery and recirculation system. Each nozzle is independently controlled for both flow rate and positioning, allowing for full coverage and easy adaptation to new part geometries. Strategic use of guarding, interlocked light fencing, and E-stop stations ensures operator safety and compliance.

Enamel-specific considerations—such as splash control, enamel formulation for high-build coverage, and separation of blasting media—were addressed through iterative design and close collaboration with materials suppliers. The final system exceeded expectations in part throughput, finish quality, and operational efficiency, offering a robust template for future automation in industrial porcelain enameling.