Revolution in painting quality and efficiency

Revolution in painting quality and efficiency

A revolution in the quality and efficiency of painting for the Nowy Styl Group

Client profile: European leader in modern office spaces

Nowy Styl is a global brand synonymous with ergonomics, design, and the highest quality in the office furniture and public spaces sectors. The company not only produces furniture but also creates work environments based on advanced analysis of user needs, acoustics, and organisational efficiency. To maintain its leadership position, Nowy Styl continually invests in technologies that guarantee perfect workmanship in every detail.

Strategic goals: Uncompromising quality and increased production capacity

The main driving force behind the investment was the need to build a painting line that would meet extreme quality requirements while simultaneously scaling up production.

Key performance indicators (KPIs) for the investment:

  • Zero Defect standard: Reduction of rejects to less than 2% (with a strict standard eliminating inclusions larger than 1 mm²).
  • Maximising efficiency: Significantly increased plant hroughput.
  • Sustainability: Dramatic reduction in raw material consumption (paints and chemicals) and optimisation of energy costs through closed heat circulation.

Challenge: Sterility in industrial conditions

The biggest challenge Nowy Styl faced when turning to Ecoline was combating micro-pollution. In the premium furniture industry, where surfaces are often smooth and subject to stringent light inspection, even the smallest speck of dust can disqualify a product.

Traditional painting systems did not guarantee such high repeatability. The challenge for Ecoline was three-dimensional:

  • Design: Creating an isolated environment resistant to the conditions in the hall.
  • Technology: Eliminating contaminants originating from within the system (paint).
  • Eco-friendliness: Integrating high-efficiency energy recovery systems.

Solution

In response to these challenges, Ecoline engineers designed a painting line based on advanced environmental separation and intelligent media management.

1. Absolute isolation: Clean Room technology

The foundation of the solution is a specialised paint booth functioning as a “Clean Room.” It has its own ventilation and humidification system, independent of the rest of the hall. Precise temperature and humidity control creates conditions that minimise the risk of dust settling on painted parts.

2. Two-stage filtration and an Ultrasonic Sieve

Eliminating external contaminants is only half the battle. The second innovative step was the use of an ultrasonic sieve. This device filters powder paint in real time, capturing the smallest particles and agglomerates that could create inclusions on the finished part.

3. Circular economy and energy recovery

Ecoline has implemented a proprietary heat recovery system from two key stages: the cooling tunnel after the drying oven and the post-polymerisation tunnel (where temperatures reach 100°C). Thanks to advanced filters, the recovered hot air is purified and directed to heat the production halls, generating significant savings, especially during the winter months.

Measurable investment results

Achieving rigorous quality standards:

The reject rate has been permanently reduced to below 2%, virtually eliminating rework and material waste costs.

A surge in processing capacity:

Thanks to automation and process optimisation, plant efficiency has increased by 60–70%, paving the way for more contracts.

Raw material optimisation:

The overspray paint recovery system allowed for reuse, drastically reducing the unit cost of painting a part.

Reducing carbon footprint and utility costs:

The use of heat recovery and modern bath filtration in the surface preparation process make this line one of the most environmentally friendly in the industry.

“The technology provided by Ecoline, thanks to innovative ideas implemented at every stage, allowed us to increase production capacity by nearly 70%. We significantly reduced our powder coating consumption, which represents significant savings and significantly reduces waste. This is an investment that combines environmental friendliness with tangible business results.”

Tomasz Pankowicz
Head of the Process Engineering and New Technology Development Department

Summary: A new standard in the furniture industry

Nowy Styl’s collaboration with Ecoline resulted in the creation of one of the most modern powder coating plants in Europe. Thanks to the bold implementation of solutions such as Clean Room and an ultrasonic sieve, Nowy Styl has set a new quality standard, proving that large-scale production can go hand in hand with precision workmanship and environmental care.