In industrial coating, quality control has always been an essential part of the process. Thickness, adhesion, finish and uniformity are some of the parameters used to verify whether a coating meets the required specifications. For many years, however, much of this quality control was carried out once the component was finished, after it had gone through all the application and curing stages.
Industrial digitalisation is beginning to change this approach. Sensors, non-contact measurement systems, automation and data management tools are making it possible to gather increasing amounts of information while the process is still underway. This opens the door to a new approach to quality control: not only verifying that the final result meets the requirements, but also obtaining data early enough to take action before problems arise.
From inspecting the result to monitoring the process
Imagine a component that has just come out of the oven. During final inspection, it is discovered that the coating thickness does not meet the required specifications. At this point, the paint has already been applied, materials have been consumed, the component has passed through the production line, and energy has been used to complete the curing process. If the result falls outside the established tolerances, corrections, repainting or repeating part of the process may be necessary.
The ability to measure earlier changes this approach. If we can determine what is happening immediately after application, we can also detect potential deviations sooner and make decisions while there is still an opportunity to act. Quality control is therefore gradually moving beyond final inspection and becoming a tool for better monitoring the entire production process.
Measuring without touching the surface
One example of this evolution is non-contact coating thickness measurement technology. At Mestres, we use CoatMaster, a system that measures coating thickness without physically touching the surface. In the case of powder coating, measurements can be taken after application and before curing.
The technology is based on an optical-thermal measurement principle: the system analyses the thermal response of the surface following a light pulse and uses this information to calculate the coating thickness. This makes it possible to obtain measurements from a coating that has not yet completed the curing process, without requiring destructive testing or necessarily waiting until the end of production.
The difference may seem to be simply a matter of timing — measuring before rather than after — but it actually represents a different approach to quality control.
When every measurement becomes valuable data
Digitalisation is not simply about replacing one measuring tool with a more advanced one. The real transformation occurs when the data collected can be recorded, compared and integrated into the quality control system.
A single measurement tells us the coating thickness of a specific component. However, multiple measurements collected over time allow us to identify trends, detect recurring deviations and gain a better understanding of how the process performs.
Current CoatMaster systems, for example, can automatically document measurement results and integrate information with quality control systems. The technology is also evolving towards direct connectivity with production lines.
This ability to collect and manage information is one of the foundations of Industry 4.0. Rather than operating as a series of independent stages, the coating line becomes a source of valuable data that helps provide a clearer understanding of what is happening throughout production.
More information for better decision-making
Obtaining data at an earlier stage can also help optimise other aspects of the process. If the coating is thicker than necessary, additional paint may be consumed without providing any extra benefit. If it is too thin, the coating may fail to deliver the expected performance.
Identifying these deviations before curing helps maintain tighter tolerances and reduces the likelihood of producing components that require subsequent corrections.
However, technology does not eliminate the need for technical expertise. Data can tell us what is happening, but understanding why it is happening still requires knowledge of the material, the component, its geometry, the application system, the coating and the process conditions.
Digitalisation provides more information; experience turns that information into informed decisions.
Towards a more connected industrial coating process
When we talk about innovation in industrial coating, we often think of new formulations, robotic application systems or more efficient technologies. However, an important part of today’s progress also lies in the ability to measure more accurately, obtain information earlier and connect the different stages of the process.
Moving from final inspection to real-time monitoring means progressing towards more predictable, traceable and repeatable processes. It is not simply about incorporating more technology, but about having access to better information to work with greater precision.
At Mestres, this combination of experience, quality control and new technologies is part of an ongoing evolution. Because the objective of industrial coating remains the same — to achieve a coating that meets the required performance standards — but the way we achieve it is becoming increasingly measurable, connected and intelligent.