Activeflush

Pure Control. Clean Systems.

Activeflush – The controlled way to flush liquid coating systems.

Reduce material loss, flushing fluid consumption, and process time with every color change.

Color changes in liquid coating systems often result in high costs, material loss, and excessive flushing fluid consumption. Activeflush restructures this process. The system combines compressed air and flushing fluid in a guided process, making the entire flushing procedure clearly controllable. Activeflush reduces material consumption, time and VOC emissions.

Who is Activeflush relevant for?

Activeflush is particularly suitable for liquid coating systems where color changes regularly consume time, material, and flushing fluid.

Applications with a high number of color changes
Processes with high flushing fluid consumption
Operations focused on resource efficiency, process reliability, and controlled cleaning procedures

Who is Activeflush relevant for?

Activeflush is particularly suitable for liquid coating systems where color changes regularly consume time, material, and flushing fluid.

Applications with a high number of color changes
Processes with high flushing fluid consumption
Operations focused on resource efficiency, process reliability, and controlled cleaning procedures

Easy handling

Activeflush guides the operator step by step through the flushing process. Complex manual procedures, moving hoses, or working with multiple containers are reduced. The control unit ensures a clearly structured and traceable process.

Time and cost savings

The use of compressed air supports the cleaning process and reduces the duration of the flushing procedure. The guided process reduces manual steps and helps lower material consumption and labor time with every color change.

Resource-saving process

Compressed air is used when emptying the system. This allows coating material to be recovered and reused. At the same time, the demand for flushing fluid and CO₂ emissions are reduced compared to conventional flushing.

Comparison: Conventional flushing vs. Activeflush

Per color change	Conventional flushing	Activeflush
Flushing steps	25	6
Quantity of flushing fluid	100 %	20–30 %
Material recovery	Approx. 40%	60–70 %
Time required	Approx. 15 min	Approx. 5 min
Costs per flush	€50-80	€20-30
Waste flushing fluid	Approx. 6.2 l	Approx. 1.4 l
Waste material	Approx. 0.6 l	Approx. 0.2 l
CO₂ consumption per flush	15 kg	4 kg

Fewer steps. Less consumption. More control.

Compared to conventional flushing, Activeflush significantly reduces the flushing process from 25 to 6 steps and decreases the time required per color change from approximately 15 minutes to around 5 minutes. At the same time, flushing fluid consumption, material loss, process time, and CO₂ emissions are significantly reduced.

How Activeflush technology works

Activeflush uses a redesigned pump inlet design featuring a poppet valve, an integrated flush connection, and a diaphragm valve. A low-pressure flushing pump supplies flushing fluid, which is mixed with compressed air. This creates a stable flushing flow that supports the cleaning process. The Activeflush control unit guides the operator step by step through the entire process.

Powerful

Flushing fluid is combined with compressed air. Together with a low-pressure flushing pump, a stable flushing flow is created that supports the process.

Economical

Large quantities of coating material can be fed back into the system. This significantly reduces material loss and the associated operating costs.

Effective

A poppet valve at the pump inlet reduces dead spaces in the fluid section and facilitates as a result more complete cleaning of the pump.

Smart & Controlled

A flush connection with a diaphragm valve controls the flushing flow. The Activeflush control unit guides step by step through the flushing process.

Guided flushing process in six steps

Compared to conventional flushing, Activeflush significantly simplifies the process. The pump is simply switched off to start the flushing process. No further settings are
required. During the process, only the spray gun and filter valve are operated in the intended sequence. Manual cleaning steps are no longer necessary. The entire process is structured via the Activeflush control unit. The operator is guided through a clearly structured flushing process in six steps. The system is first emptied using compressed air, then cleaned using a combination of compressed air and flushing fluid, and finally dried in a controlled manner.

1. Empty the suction hose
The suction hose is emptied using compressed air (spray nozzle removed) and coating material is recovered. The diaphragm valve is open and the suction hose is positioned above the liquid level in the container.

2. Emptying Pump
The pump is emptied using compressed air and without flushing fluid. The diaphragm valve is closed and the pump runs slowly. Coating material is recovered via the filter and spray gun.

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3. Rinsing the suction hose
The suction hose is rinsed using compressed air (spray nozzle removed) and flushing fluid. The diaphragm valve is open and the suction hose is positioned in the collection container.

4. Flushing the pump
The pump is flushed using compressed air and flushing fluid. The diaphragm valve is closed and the pump runs slowly. Filter circulation, material hose, and spray gun are cleaned in a targeted manner.

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5. Drying the suction hose
The suction hose is dried using compressed air. The flushing fluid is returned, the diaphragm valve is open, and the suction hose is positioned in the waste container.

6. Drying the pump
Finally, the pump is dried using compressed air. The flushing fluid is returned, the diaphragm valve is closed, and the pump runs slowly. Drying takes place via the filter, small circulation, material hose, and spray gun.

5. Drying the suction hose
The suction hose is dried using compressed air. The flushing fluid is returned, the diaphragm valve is open, and the suction hose is positioned in the waste container.

Example configuration:
Mobile WAGNER Leopard pump set with Activeflush extension.

Clean systems.
Controlled processes.
Resource-saving operation.

Activeflush supports a structured flushing process, reduces material loss, flushing fluid consumption, and process time with every color change, and ensures controlled cleaning of pumps and liquid coating systems.

Product brochure

The brochure contains all important information about the Activeflush technology.

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Contact form

Interested in Activeflush and its patented technology? Feel free to send us a request using the contact form below.