Select your favourite machine
Reducing paint waste with PST Line II: real use cases and efficiency
Discover how the PST Line II reduces paint waste through real-world use cases, advanced automation, and precise material application.
In modern manufacturing, waste reduction is no longer optional—it’s a strategic priority. Particularly in sectors like cosmetics, pharmaceuticals, and automotive, where high volumes of painted plastic components are produced, optimizing material usage is essential. Tapematic’s PST Line II has redefined coating efficiency by drastically reducing paint waste while maintaining top-tier quality and speed. With real-world applications across several industries, this technology is proving its value not just in theory, but in practice.
The PST Line II is the core platform of Tapematic’s surface coating technology. It is a modular, fully automated inline system designed for three-dimensional components, offering UV spray coating, vacuum sputtering, and integrated cleaning and pretreatment in one continuous cycle.
Every element of the PST Line II is built for precision. The system applies coatings with controlled thickness and uniformity, ensuring consistent coverage across even the most complex shapes. Its automation reduces overspray, minimizes reject rates and significantly cuts down the amount of paint used per unit—without sacrificing finish quality.
Traditional coating systems often rely on batch processing, which can result in significant material loss during setup, transfer, or overspray collection, high rejection rates The PST Line II eliminates these inefficiencies through a fully inline, closed-loop process.
From the moment a part enters the cleaning module to the final UV curing and sputtering stages, each step is precisely calibrated. This ensures:
- Accurate material application
- No unnecessary accumulation or runoff
- Seamless transitions between process phases
- Clean handling and minimal contamination
By streamlining the workflow and integrating every operation, the PST Line II minimizes disruptions and virtually eliminates paint waste.
One leading cosmetics manufacturer adopted the PST Line II to coat high-end perfume bottle caps and skincare jars. These components required a flawless, mirror-like finish with zero visual defects.
With traditional systems, high rejection rates and overspray losses were common. After implementing the PST Line II:
- Paint waste was reduced by over 40%
- First-pass yield increased by 30%
- Cycle times improved by 25%
- Coating thickness became more consistent
The switch not only saved costs but also aligned with the company’s sustainability goals by lowering chemical consumption and energy usage.
One of the key advantages of Tapematic’s system is the integrated pretreatment module. Instead of using a cleanroom—which Tapematic does not incorporate—the PST Line II uses inline cleaning and surface activation technologies to prepare components before coating.
This step is crucial for reducing waste, as it ensures optimal adhesion of paint to the substrate. Poor adhesion leads to higher rejection rates and the need for rework, which consumes additional materials and energy. With Tapematic’s method:
- Surface contaminants are removed without manual intervention
- Static charges are neutralized
- Paint adhesion improves, reducing defects
This contributes directly to waste reduction and process reliability.
For companies requiring a smaller footprint, Tapematic offers the PST Line C. Though it is not modular like the PST Line II, it delivers the same precision, coating performance, and waste-saving benefits.
The PST Line C is suitable for a wide range of component shapes, not just cylindrical parts. Its all-in-one design makes it ideal for small-to-medium-scale operations that prioritize both efficiency and sustainability.
Overspray is one of the most common causes of paint waste in conventional spray systems. Tapematic addresses this with highly refined robotic control of the spray heads, synchronized with the conveyor system. Real-time adjustments ensure paint is only applied where needed, in the exact amount required.
Benefits include:
- Lower material usage per unit
- Cleaner work environment
- Less frequent maintenance
- Reduced filter and booth waste
The precision of the automatic system also ensures aesthetic consistency, even across high-volume production runs.
Paint waste isn’t limited to liquid loss—it also includes the environmental impact of solvents and volatile organic compounds (VOCs) released during the coating process. Tapematic’s UV spray coating technology drastically reduces these emissions by replacing traditional solvent-based methods with energy-efficient, instant-curing UV coatings.
This results in:
- Near-zero VOC output
- Shorter curing times
- Lower heat requirements
- Safer working conditions
By consuming fewer resources and emitting fewer pollutants, Tapematic’s systems support greener production practices.
The PST Line II integrates advanced monitoring systems that track material usage in real time. Manufacturers can access detailed data on:
- Coating thickness
- Paint flow rates
- Spray duration
- Reject ratios
This data allows for immediate process adjustments and long-term optimization, helping to further reduce waste while ensuring regulatory compliance and quality control. In industries such as pharmaceuticals, where documentation and traceability are essential, this feature is a key advantage.
Beyond cosmetics, Tapematic has implemented the PST Line II in sectors such as beverage packaging and high-performance automotive components. One automotive supplier, previously struggling with paint loss due to irregular part shapes, reported:
- 35% reduction in paint consumption
- Improved surface consistency on complex geometries
Such outcomes underline the versatility of Tapematic’s systems across industries where material efficiency and product integrity are both critical.
Tapematic’s commitment to precision engineering, sustainability, and productivity makes it a reliable partner for manufacturers worldwide. With the PST Line II and PST Line C, the company offers real-world solutions that directly address one of the industry’s biggest challenges: reducing paint waste without compromising quality.
By leveraging automation, integrated cleaning, and intelligent spray control, Tapematic continues to set the benchmark for efficient, sustainable surface treatment technology.
PST Line II: precision engineering for optimized coating
The PST Line II is the core platform of Tapematic’s surface coating technology. It is a modular, fully automated inline system designed for three-dimensional components, offering UV spray coating, vacuum sputtering, and integrated cleaning and pretreatment in one continuous cycle.
Every element of the PST Line II is built for precision. The system applies coatings with controlled thickness and uniformity, ensuring consistent coverage across even the most complex shapes. Its automation reduces overspray, minimizes reject rates and significantly cuts down the amount of paint used per unit—without sacrificing finish quality.
Inline coating process: minimizing waste from start to finish
Traditional coating systems often rely on batch processing, which can result in significant material loss during setup, transfer, or overspray collection, high rejection rates The PST Line II eliminates these inefficiencies through a fully inline, closed-loop process.
From the moment a part enters the cleaning module to the final UV curing and sputtering stages, each step is precisely calibrated. This ensures:
- Accurate material application
- No unnecessary accumulation or runoff
- Seamless transitions between process phases
- Clean handling and minimal contamination
By streamlining the workflow and integrating every operation, the PST Line II minimizes disruptions and virtually eliminates paint waste.
Real use case: cosmetic packaging with zero-tolerance for waste
One leading cosmetics manufacturer adopted the PST Line II to coat high-end perfume bottle caps and skincare jars. These components required a flawless, mirror-like finish with zero visual defects.
With traditional systems, high rejection rates and overspray losses were common. After implementing the PST Line II:
- Paint waste was reduced by over 40%
- First-pass yield increased by 30%
- Cycle times improved by 25%
- Coating thickness became more consistent
The switch not only saved costs but also aligned with the company’s sustainability goals by lowering chemical consumption and energy usage.
Built-in pretreatment for higher efficiency
One of the key advantages of Tapematic’s system is the integrated pretreatment module. Instead of using a cleanroom—which Tapematic does not incorporate—the PST Line II uses inline cleaning and surface activation technologies to prepare components before coating.
This step is crucial for reducing waste, as it ensures optimal adhesion of paint to the substrate. Poor adhesion leads to higher rejection rates and the need for rework, which consumes additional materials and energy. With Tapematic’s method:
- Surface contaminants are removed without manual intervention
- Static charges are neutralized
- Paint adhesion improves, reducing defects
This contributes directly to waste reduction and process reliability.
PST Line C: compact system, same efficiency
For companies requiring a smaller footprint, Tapematic offers the PST Line C. Though it is not modular like the PST Line II, it delivers the same precision, coating performance, and waste-saving benefits.
The PST Line C is suitable for a wide range of component shapes, not just cylindrical parts. Its all-in-one design makes it ideal for small-to-medium-scale operations that prioritize both efficiency and sustainability.
Automated spray controls reduce overspray
Overspray is one of the most common causes of paint waste in conventional spray systems. Tapematic addresses this with highly refined robotic control of the spray heads, synchronized with the conveyor system. Real-time adjustments ensure paint is only applied where needed, in the exact amount required.
Benefits include:
- Lower material usage per unit
- Cleaner work environment
- Less frequent maintenance
- Reduced filter and booth waste
The precision of the automatic system also ensures aesthetic consistency, even across high-volume production runs.
Sustainability in action: reducing VOCs and resource usage
Paint waste isn’t limited to liquid loss—it also includes the environmental impact of solvents and volatile organic compounds (VOCs) released during the coating process. Tapematic’s UV spray coating technology drastically reduces these emissions by replacing traditional solvent-based methods with energy-efficient, instant-curing UV coatings.
This results in:
- Near-zero VOC output
- Shorter curing times
- Lower heat requirements
- Safer working conditions
By consuming fewer resources and emitting fewer pollutants, Tapematic’s systems support greener production practices.
Monitoring and traceability for process optimization
The PST Line II integrates advanced monitoring systems that track material usage in real time. Manufacturers can access detailed data on:
- Coating thickness
- Paint flow rates
- Spray duration
- Reject ratios
This data allows for immediate process adjustments and long-term optimization, helping to further reduce waste while ensuring regulatory compliance and quality control. In industries such as pharmaceuticals, where documentation and traceability are essential, this feature is a key advantage.
Multi-industry success with minimal paint waste
Beyond cosmetics, Tapematic has implemented the PST Line II in sectors such as beverage packaging and high-performance automotive components. One automotive supplier, previously struggling with paint loss due to irregular part shapes, reported:
- 35% reduction in paint consumption
- Improved surface consistency on complex geometries
Such outcomes underline the versatility of Tapematic’s systems across industries where material efficiency and product integrity are both critical.
Forward-thinking engineering for a sustainable future
Tapematic’s commitment to precision engineering, sustainability, and productivity makes it a reliable partner for manufacturers worldwide. With the PST Line II and PST Line C, the company offers real-world solutions that directly address one of the industry’s biggest challenges: reducing paint waste without compromising quality.
By leveraging automation, integrated cleaning, and intelligent spray control, Tapematic continues to set the benchmark for efficient, sustainable surface treatment technology.