Greenfield Engineering: Raising the bar in powder coating
A Strategic Investment in Quality, Consistency and Sustainability
Greenfield Engineering continues to strengthen its position as one of the UK's leading contract sheet metal manufacturing businesses through significant investment in advanced manufacturing technology. Operating from more than 80,000 sq ft of production space located across two facilities in Holsworthy in the South West region of the UK, the company provides precision sheet metal fabrication, powder coating, assembly and integrated manufacturing solutions to customers operating across a wide range of sectors including furniture, lighting, laboratory equipment, transport, electronic enclosures and industrial technology.
As customer expectations continue to evolve, Greenfield Engineering recognised the need to modernise a powder coating facility that had served the business reliably for more than 25 years. While the existing plant had supported many years of successful production, increasing product complexity, growing customer requirements and the company's wider investment in advanced manufacturing technologies highlighted the opportunity to create a finishing facility capable of matching the standards achieved throughout the rest of the business. The result is one of the most advanced powder coating installations in the UK, delivered in partnership with TD Finishing and WAGNER.
Creating a Future-Proof Finishing Operation
The powder coating project forms part of a wider programme of strategic investment across Greenfield Engineering's manufacturing operations. Recent investments have included fibre laser cutting technology, automated punching systems, robotic bending solutions, advanced quality assurance equipment, renewable energy generation and digital manufacturing systems. The objective was clear: create a powder coating operation capable of delivering exceptional finish quality, repeatability and efficiency while supporting future growth. Frank Green, Founder of Greenfield Engineering, explains:
“Our customers expect consistently high standards. We wanted a process that delivered the same high-quality finish every time, regardless of operator experience. This investment establishes the benchmark for the future of our finishing operations.” Working alongside TD Finishing and WAGNER, Greenfield implemented a complete line modernisation incorporating 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 during late 2025, with production commencing in January 2026.
Why WAGNER?
Selecting the right technology partner was a critical part of the project. Following a detailed review of available systems, Greenfield Engineering selected WAGNER's latest generation IPS powder application technology, supported by the company's established UK presence and after-sales support infrastructure. Director Daniel Green commented: “This project was not simply about replacing equipment. It was about creating a future-proof finishing operation capable of supporting increasing customer expectations, greater product complexity, and our long-term growth plans. WAGNER's commitment to the UK market, combined with the capabilities of the IPS platform and strong after-sales support, made the solution a natural fit.” The installation includes WAGNER's S-Line automatic powder coating system with S-Cube booth technology, designed specifically for manufacturers operating high-mix production environments where flexibility and efficiency are equally important.
Built for High-Mix Manufacturing
One of Greenfield Engineering's key requirements was the ability to manage frequent colour changes while maintaining productivity and finish quality. With more than ten colour changes regularly occurring during a shift, minimising downtime was essential. The self-cleaning S-Cube booth technology significantly reduces cleaning times, enabling rapid transitions between colours while maintaining stable airflow conditions and consistent coating performance. The system incorporates twelve automatic PEA-X1 powder guns alongside dedicated guns for underside coating, ensuring complete coverage of larger and more complex components. A dedicated manual coating station equipped with WAGNER PEM-X1 controlled by the new Sprint 2 Expert controllers provides additional flexibility for intricate geometries and specialist finishing requirements. Together, these technologies allow Greenfield to maintain exceptional coating quality across a diverse product range while supporting efficient production flow.
Intelligent Automation Through 3D Coating Technology
At the heart of the installation is WAGNER's advanced 3D coating technology. Each component entering the booth is scanned automatically, allowing the system to identify the geometry of the workpiece in real time. Automatic gun positioning technology continuously adjusts spray distances to optimise coverage and powder utilisation without the need for manual programming. The system also recognises gaps between components and automatically disables powder delivery when no product is present, reducing unnecessary powder consumption and improving overall process efficiency. For Greenfield Engineering's high-mix manufacturing environment, this technology delivers consistent coating thickness across a wide variety of product shapes while minimising overspray and reducing waste.
The UK's first WAGNER IPS powder centre
A key feature of the installation is the IPS powder centre, the first system of its type installed within the United Kingdom. The IPS platform combines powder feeding, conditioning, sieving, and colour change management within a single integrated system. Intelligent sensors continuously monitor powder flow, weight, pressure and fill levels to ensure optimal performance throughout production. The system's Smart Feeding Technology maintains a stable powder transfer rate even during extended production runs, helping to eliminate process variation and improve consistency. For Greenfield Engineering, this represents a significant advancement in process control and repeatability. As Frank Green explains: “We're finding with our new system that the standard is set by the system, not by the operator. We're now achieving a level of consistency that simply wasn't possible before.”
Sustainability and Operational Efficiency
Sustainability was a key consideration throughout the design of the new facility. The installation incorporates WAGNER's Energy Efficiency Package (EEP), combining an optimised mono-cyclone recovery system and advanced filtration technology to reduce energy consumption while maximising powder recovery performance. The improved airflow design reduces pressure losses throughout the system, helping to lower operating costs and reduce environmental impact. At the same time, improved powder management and recovery minimise waste and improve material utilisation. These benefits complement Greenfield Engineering's broader sustainability strategy, which includes significant investment in on-site solar generation, waste reduction initiatives, and internationally recognised environmental management systems.
Delivering Measurable Results
Since commissioning, Greenfield Engineering has experienced significant improvements across multiple aspects of the finishing process.
Key benefits include:
- Improved coating consistency and repeatability.
- Enhanced finish quality across complex product ranges.
- Reduced powder waste and overspray.
- Increased process control and visibility.
- Improved productivity through faster colour changes.
- Reduced operator dependency.
- Lower environmental impact through improved energy efficiency and recovery performance.
Managing Director Gary Burnard commented: “It's a win-win situation. We're achieving improvements in productivity while simultaneously reducing waste and supporting our environmental objectives. The performance of the installation has exceeded expectations.”
Looking to the Future
The success of the project has reinforced Greenfield Engineering's commitment to continuous investment in advanced manufacturing technologies. As customer requirements continue to evolve, the company remains focused on expanding its capabilities, increasing automation, and further enhancing quality, efficiency and sustainability throughout its operations. Gary Burnard concludes: “The results achieved through this investment have given us confidence to continue investing in the future. Our focus remains on delivering world-class manufacturing solutions and creating long-term value for our customers.” For Frank Green, the project represents an important milestone in the company's ongoing development: “The investment has transformed our finishing capability. The consistency, appearance and overall quality of the coated product have exceeded expectations and further strengthened the service we provide to our customers. It has taken our powder coating operation to another level.”
