Greenfield Engineering Modernizes Powder Coating Line With WAGNER Automation

Need to Know

Greenfield Engineering completed a full powder coating line modernization incorporating automated pretreatment, curing, conveying and powder recovery.
WAGNER’s 3D scanning technology adjusts gun positioning based on part geometry and stops powder delivery when no workpiece is detected.
Installation was completed in late 2025, with production beginning in January 2026.

Greenfield Engineering has modernized its powder coating operation at its manufacturing facilities in Holsworthy, England, working with TD Finishing and WAGNER Industrial Solutions.

The contract sheet metal manufacturer replaced a finishing facility that had been in service for more than 25 years. The new line incorporates a fully automated five-stage pretreatment process, drying and curing ovens, new conveyor systems, powder recovery technology and automated powder application equipment.

The installation includes WAGNER’s S-Line automatic powder coating system with S-Cube booth technology and 12 automatic PEA-X1 powder guns, along with dedicated guns for underside coating. A separate manual coating station supports parts with more complex geometries. Greenfield regularly handles more than 10 color changes during a shift, according to WAGNER.

The system also incorporates automated 3D workpiece scanning. As components enter the booth, the technology identifies part geometry and adjusts spray-gun positioning and distance. The system can identify gaps between components and stop powder delivery when no product is present, which is intended to reduce overspray and powder consumption.

The installation also includes what WAGNER describes as the first IPS powder center of its type installed in the United Kingdom. The system combines powder feeding, conditioning, sieving and color-change management, with sensors monitoring parameters including powder flow, weight, pressure and fill levels.

Installation was completed in late 2025, and Greenfield began production on the line in January 2026. WAGNER said the manufacturer has since reported improvements in coating consistency, finish quality, powder utilization, color-change productivity and process control.

For more on application equipment, booths, curing and automation, see PCI’s coverage of powder coating equipment.