Digital Intelligence in Powder Coating
June 1, 2025
WAGNER has announced Flowsense, a new technology available as an optional upgrade on all new Wagner PXS powder centers. It is a smart system that measures and automatically controls powder output, offering consistent layer thickness, reducing powder consumption and enabling reproducible results.
With Flowsense, each individual feeding element is equipped with high-precision sensors that measure and control the quantity of powder transported to the respective application, automatically compensating for variations caused by fluidization and fluctuating powder levels. It constantly monitors the powder flow for each gun individually, comparing and adjusting output to target values set by the user. The optimal amount of powder required can be saved as a recipe, ensuring consistent and reproducible results without the need for manual adjustments.
By precisely adjusting powder output to match targeted specifications, Flowsense provides consistent layer thickness. This precision results in reduced powder consumption and safety margins. For instance, for a typical system covering 6,462,000 sq. ft. annually and a powder cost of $3.50/lb., reducing the average coating thickness by .2 mils (6 microns) could save approximately $42,570 per year. Maintaining coating thickness within certain limits is also an important criterion for certification by quality associations for industrial coating.
Flowsense is configured and operated through the powder center's touchscreen and operates primarily in the background. It displays relevant information as needed and features intuitive user guidance for operation and predictive maintenance. A simple traffic light system clearly displayed on the touchscreen provides the status of each collector nozzle. Notifications to replace wear parts appear only when absolutely necessary, extending the life of nozzles and reducing operating costs.
Flowsense will also be integrated into WAGNER COATIFY, a web-based platform that delivers real-time detailed system knowledge 24/7. COATIFY provides intelligent visualization of the coating system, enabling tighter process control and shorter reaction times, which increases system availability and productivity.
For more information contact:
Wagner Spraytech Inc.
1770 Fernbrook Lane
Plymouth, MN 55440
763-553-7000
custserv@wagnersprattech.com
< back