Executive summary

Agricultural equipment manufacturers must balance durability, production efficiency and cost control while meeting increasing expectations for sustainability and finish quality.

UNIA Group, a leading European OEM with over 140 years of manufacturing experience, modernized its coating operations by implementing advanced powder and liquid finishing technologies.

Figure 1: UNIA Group modernized its coating operations by implementing advanced powder and liquid finishing technologies. Source: Sames

The result: improved uptime, consistent coating quality and more efficient use of materials — demonstrating how integrated coating solutions can directly impact production performance and long-term competitiveness.

Industry challenge

Manufacturers of heavy equipment and fabricated metal products commonly face:

• Inconsistent coating quality across high-mix production
• Excessive downtime during color changes or maintenance
• Material waste due to inefficient application systems
• Pressure to improve sustainability without increasing costs

Traditional coating setups often struggle to deliver both high throughput and repeatable finish quality, especially in operations with frequent product changeovers.

Figure 2: UNIA Group produces durable, field-ready equipment where coating performance is critical to corrosion resistance, product longevity and brand perception. Source: Sames

Customer overview

• Company: UNIA Group
• Industry: Agricultural machinery manufacturing
• Facility focus: Grudziądz, Poland, production plant (tillage equipment)
• Experience: 140+ years

UNIA Group produces durable, field-ready equipment where coating performance is critical to corrosion resistance, product longevity and brand perception.

Project objective

UNIA Group set out to:

• Improve coating consistency across production runs
• Reduce downtime tied to color changes and maintenance
• Increase automation within finishing operations
• Enhance long-term durability of coatings

The company prioritized solutions that could deliver repeatable results at scale while supporting future growth.

Figure 3: UNIA implemented a combination of automated powder and liquid coating technologies. Source: Sames

Solution overview

To meet these objectives, UNIA implemented a combination of automated powder and liquid coating technologies.

Powder coating system enhancements:

• Automated booth with quick color change capability
• Reduced cleaning time between product runs
• Improved responsiveness for multi-color production environments

Liquid coating process control:

• Precision mixing and dosing system for consistent material ratios
• High-reliability pumps to maintain continuous operation

These systems ensure stable application conditions, minimizing variability across shifts and operators.

Application technology

• High-efficiency spray equipment to improve transfer rates
• Electrostatic and Airmix technologies for uniform coverage and finish quality
• Integration into automated production workflows

Results and performance improvements

1. Increased production efficiency

• Reduced downtime during color changes
• Improved line up time with reliable, continuous operation
• Streamlined workflow through automation

2. Improved coating quality

• Consistent film builds and finish appearances
• Enhanced durability for harsh field conditions
• Reduced rework and quality variability

3. Material and cost optimization

• Lower coating waste due to improved transfer efficiency
• More accurate material usage through controlled mixing and delivery
• Reduced total cost of ownership over time

Sustainability impact

Rather than relying on major process overhauls, UNIA achieved sustainability improvements through operational efficiency gains, including:

• Reduced overspray and material loss
• Lower energy consumption from minimized downtime
• Less rework and scrap

These improvements align with broader industry trends, where sustainability is increasingly tied to process optimization and waste reduction rather than standalone initiatives.

Key engineering takeaways

For manufacturers evaluating coating system upgrades:

Focus on uptime

Downtime — especially during color change — is often the largest hidden cost driver.

Prioritize process control

Precise material mixing and delivery directly impacts coating consistency and waste reduction.

Evaluate transfer efficiency

Improving transfer rates can significantly reduce coating consumption and operating costs.

Think in systems, not components

The biggest gains come from integrating powder, liquid and automation technologies — not optimizing them individually.

Conclusion

UNIA Group’s coating line modernization demonstrates how targeted investments in automation, process control and application technology can deliver measurable improvements in:

• Production efficiency
• Coating quality
• Material utilization

For manufacturers in agriculture, heavy equipment and fabricated metals, the case highlights a practical path to improving performance without compromising operational flexibility.

Looking to reduce downtime and improve coating consistency?

Connect with a Sames application expert to evaluate current processes and identify opportunities to improve efficiency, quality and overall performance.