The solution
Working together with TD Finishing and WAGNER, Greenfield Engineering implemented a complete line modernisation. The new installation incorporates a fully automated five-stage pre-treatment process, advanced drying and curing ovens, new conveyor systems, intelligent powder recovery technology and state-of-the-art powder application equipment. Installation was completed in late 2025, with production commencing in January 2026.
Following a detailed review of available systems, Greenfield Engineering selected the latest generation of the WAGNER IPS coating center. In addition to the technology itself, WAGNER’s strong presence in the UK market and comprehensive after-sales support played an important role in the decision. The IPS coating center is the first system of its kind installed in the United Kingdom and combines powder feeding, conditioning, sieving and colour change management within a single integrated platform. Intelligent sensors continuously monitor key process parameters to ensure optimum conditions for consistently high coating quality.
The installation also includes a WAGNER S-Line automatic powder coating system with S-Cube booth technology. The system enables rapid colour changes while maintaining stable coating conditions and significantly reducing downtime. Twelve automatic PEA-X1 powder guns, together with dedicated guns for underside coating, ensure reliable coverage even for larger and more complex components. A dedicated manual coating station equipped with a Sprint 2 Expert provides additional flexibility for particularly challenging geometries. The installation also incorporates WAGNER’s Energy Efficiency Package (EEP), which combines an optimised mono-cyclone recovery system with advanced filtration technology. This improves powder recovery, reduces pressure losses and increases the overall energy efficiency of the coating line.
Another highlight of the installation is WAGNER’s advanced 3D coating technology. The system automatically scans each workpiece as it enters the booth and adjusts gun positioning and powder delivery accordingly. This ensures consistent coating thicknesses, reduces overspray and minimises material waste.
