{"id":9910,"date":"2026-03-10T13:21:50","date_gmt":"2026-03-10T18:21:50","guid":{"rendered":"https:\/\/informatech.energir.com\/?p=9910"},"modified":"2026-03-20T15:57:13","modified_gmt":"2026-03-20T20:57:13","slug":"manufacturing-leader-cuts-energy-use-by-50-and-improves-carbon-footprint-with-efficient-paint-line","status":"publish","type":"post","link":"https:\/\/informatech.energir.com\/?p=9910&lang=en","title":{"rendered":"How can you cut energy consumption in half with an efficient painting line?"},"content":{"rendered":"
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To improve operational efficiency and product quality, a manufacture made a significant investment in her its powder coating line, using innovative technologies to reduce energy consumption and greenhouse gas (GHG) emissions. What are these technologies and why are they so effective? What economic and environmental gains did they produce? What other technologies can improve such a facility’s energy performance? Learn all about it in this article.<\/strong><\/h2>\n<\/div>\n<\/div><\/div><\/div><\/div>
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Reducing energy requirements while boosting efficiency<\/h3>\n

The automated paint line under study is used to prepare, paint and cure the produced parts. As the primary energy consumers, the ovens at the end of the line offer the greatest potential for savings. Exhaust is also required during paint application to maintain a clean environment and to replace stale air with a fresh air supply.<\/p>\n

Our customer implemented three efficient technologies on the production line to limit natural gas consumption and boost efficiency:<\/p>\n\n\n\n\n\n
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Variable-frequency drives (VFD) on exhaust fans<\/strong><\/p>\n<\/td>\n<\/tr>\n

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Infrared thermoreactors for rapid curing<\/strong><\/p>\n<\/td>\n<\/tr>\n

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Air curtains at oven openings<\/strong><\/p>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<\/div><\/div><\/div>

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1. Variable-frequency drives (VFD) on exhaust fans<\/h3>\n

VFDs adjust fan motor speed to precisely regulate airflow based on the paint line’s actual needs. During the initial purge**, fans run at full capacity; then VFDs reduce their speed to limit the exhaust of hot air. As a result, the volume of new, cold air to be heated is smaller, reducing the thermal load on the burners. With this technology, we estimate savings of 31,000 m3<\/sup> of natural gas per year.*<\/strong><\/p>\n

2. Infrared thermoreactors for rapid curing<\/h3>\n

The infrared thermoreactors chosen by the customer use natural gas radiant panels. The panels’ wavelength is optimized such that only the powder absorbs the energy, thereby eliminating the need to heat the entire metal mass of the part. As a result, the temperature ramp-up time was reduced from ten (10) minutes to two (2), allowing for shorter ovens and lower heating power. This technology saves an estimated 39,000 m3<\/sup> of natural gas per year,*<\/strong> while also improving paint quality and increasing production speed.<\/p>\n

3. Air curtains at oven openings<\/h3>\n

Air curtains, a technology we discuss in detail in this article<\/a>, create a thermal barrier at openings using high-speed airflow, which limits heat exchange between the oven interior and the outside environment. By reducing heat loss from infiltration, these curtains save an estimated 24,000 m3<\/sup> of natural gas per year.<\/strong>*<\/strong><\/p>\n<\/div>\n<\/div><\/div><\/div><\/div>

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Demonstrated results<\/h3>\n

By leveraging these technologies, the customer was able to achieve its financial and environmental goals <\/span>while shortening its payback period.   Thanks to financial support from the Government of Québec’s <\/span>ÉcoPerformance<\/a><\/span> program and a grant from the <\/span>Studies and Implementation Component<\/a><\/span> of Énergir’s energy efficiency program.<\/span><\/p>\n

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GHG emissions reduction: 176 tonnes of CO2<\/sub>\/year***<\/td>\n<\/tr>\n
Energy savings: 93,600 m3<\/sup> of natural gas\/year<\/td>\n<\/tr>\n
Financial savings: $50,000\/year<\/td>\n<\/tr>\n
Payback period: 2.5 years with financial assistance from the ÉcoPerformance program and Énergir<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n