A powder coating plant uses electrostatic powder paints that are applied dry and then cured in an oven at temperatures between 160°C and 200°C. It offers excellent mechanical resistance, zero solvent emissions and a high transfer efficiency (up to 99% of the powder can be recovered). A liquid painting plant, on the other hand, uses paints in liquid form (water or solvent based) and is preferred where special finishes, complex metallic colours or treatments on materials unsuited to oven heat are required. Varco International designs and builds both types, in manual and automatic versions.

Lead times depend on the complexity of the plant and on the level of automation required. As a general rule, a standard manual plant takes 8 to 16 weeks from contract signature to start-up. For complex automatic plants or plants with motorised overhead conveyors, lead times can extend to 20–30 weeks. Varco International manages the entire process in-house — design, manufacturing, installation and testing — giving the customer a single point of contact and ensuring the agreed schedule is met.

Yes. Varco International also specialises in the extension, modification and refurbishment of existing painting plants. During the design stage we analyse the factory layout, the current production flow and the structural constraints, so that the new plant can be integrated without interrupting production more than strictly necessary. Individual components can be added or replaced (a washing booth, a new oven, a conveyor system), or a completely new plant can be built alongside the existing one.

Yes. Varco International designs painting plants that are ready for Industry 4.0, with advanced control systems, latest-generation electrical panels and internet connectivity for remote assistance and monitoring. This makes it possible to collect process data in real time, plan predictive maintenance and qualify for the tax incentives that Italian legislation provides for Industry 4.0 capital equipment.

All painting plants designed and built by Varco International comply with the safety regulations in force on industrial hygiene, atmospheric emissions and fire prevention. In particular, the spray booths and the extraction systems are sized to meet solvent concentration limits (LEV) and VOC (Volatile Organic Compound) emission regulations. The company is ISO 9001:2015 certified by TÜV, which guarantees a structured quality system audited by an independent body.

The painting plants designed and built by Varco International can handle a wide range of materials, thanks to the ability to configure pre-treatment cycles, temperatures and application systems specific to each substrate:

Steel, iron, aluminium, cast iron, brass, marble, ceramic, glass, fibreglass, wood, plastic, rubber, expanded polyurethane and polystyrene.

Each material calls for a different technical approach: ferrous metals, for example, benefit from a phosphating cycle that maximises adhesion and corrosion resistance, while heat-sensitive materials such as plastic, rubber and polystyrene require application systems and ovens calibrated to lower temperatures. Aluminium is treated with dedicated pre-treatment cycles (chromating or nanotechnology) to guarantee a durable finish. For materials such as fibreglass, expanded polyurethane and ceramic, Varco International assesses case by case which painting technology is best suited — powder or liquid — according to the specifications of the finished product.

For materials not listed here, or for unusual applications, contact us for a free consultation: our company is always ready to analyse new market requirements and develop tailor-made solutions.

Yes. Varco International powder coating plants are suitable for coating steel, aluminium, cast iron, zinc and metal alloys in general. The pre-treatment cycle (phosphating, degreasing, passivation) is sized according to the material to be treated, to guarantee maximum powder adhesion and corrosion resistance of the finished product. In particular cases — for example non-metallic substrates or heat-sensitive materials — liquid painting is evaluated instead.

Yes. Varco International designs custom spray booths and plants, with no standard limits on the size of the parts to be treated. We have built plants for sectors that require the treatment of large components, such as agricultural vehicles, industrial pipes, metal structures and heavy steelwork. The plant layout, the handling system (hangers, hooks, trolleys) and the booth dimensions are all designed around the specifications of the customer's parts.

An automatic painting plant guarantees a consistent finish quality (removing the variables introduced by the operator), a faster cycle and higher hourly output, lower paint consumption thanks to precise control of the application parameters, and a lower labour cost per unit produced at high volumes. Manual plants remain the best choice for flexible production, small batches or parts with widely varying geometries that require operator intervention. Varco International works with the customer to identify the solution best suited to the volume and type of production.

To receive a quotation you can contact Varco International through the contact form on varco.net, by email at varco@varco.net, or by telephone on +39 044 260 03 55. To prepare an accurate technical proposal it helps to have some basic information: the type and material of the parts to be coated, their maximum dimensions, the estimated production volume (parts per day or kg per hour), the type of finish required (powder or liquid), and an approximate layout of the space available. Varco International works alongside the customer from the very first analysis to find the most efficient solution.

With over 30 years of activity and hundreds of installations throughout Italy and abroad, Varco International painting plants suit an extraordinarily wide range of manufacturing sectors. Below are all the fields in which we have designed and installed plants:

Automotive, military aeronautics, aerospace, agriculture and agricultural equipment, car accessories, truck accessories, gas fittings, motorcycle accessories, gate and door hardware, fencing components, welding accessories, window and door hardware, fire protection, furniture, urban furniture, gift articles, forklift servicing, automation systems, iron structural work, mechanical structural work, metal structural work, heavy metal structural work, metalworking, vehicle body shops, industrial closures, tanneries, steel construction, mechanical construction, metal construction, boat building, water treatment plants, purification, vehicle diagnostics, building and construction, electrical equipment, electromechanics, electronics, energy, joinery, foundries, ovens, cableways, electroplating, ice-cream equipment, hobby products, lighting, automation plants, extrusion plants, ventilation systems, photovoltaic systems, equestrian facilities, industrial plants, technological systems, industry, infrastructure, engineering, soundproofing, irrigation, sheet metal roofing, laundry, industrial laundries, stainless steel processing, carbon fibre processing, sheet metal working, wood processing, marble processing, mechanical machining, metal machining, logistics, metal polishing, furniture polishing, park maintenance, maintenance services, marine maintenance, road maintenance, mechanics, precision engineering, metal and mechanical engineering, defence, industrial assembly, marine sector, forklift rental, nuclear, subcontract workshops, mechanical workshops, playgrounds, truck parts, plastic components, pneumatics, railway products, gas products, industrial products, welding products, metal cleaning, engine overhaul and repair, lifting equipment overhaul, waste container refurbishment, wheel refurbishment, alloy wheel refurbishment, forklift repair, alloy rim repair, agricultural machinery repair, pump repair, industrial vehicle repair, general repairs, shot blasting machines, shot blasting, shot blasting and painting, screen printing, marine services, iron and steel industry, handling systems, fire protection systems, heating systems, solutions for the visually impaired, printing, moulds, scientific instrumentation, district heating, turning, metal shearing, transport, electroplating treatments, heat treatments, water treatment, tooling, industrial vehicles, subcontract painting, endoprene coating, wood coating, galvanising, galvanising and structural work, galvanising, painting and shot blasting.

This variety reflects Varco International's ability to design customised solutions for any surface pre-treatment and finishing requirement, whatever the sector or the complexity of the production process. If your sector is not listed, get in touch: we design bespoke plants for unconventional applications too.

Yes. Varco International manages the entire life cycle of the plant in-house — design, manufacturing, installation and testing — giving the customer a single point of contact from contract signature to production start-up.

The assembly of the painting plant is carried out at the customer's factory by the company's own qualified technicians and covers:

– positioning and mechanical assembly of the structures: spray booths, curing and drying ovens, washing booths and tunnels;

– assembly of the conveying line, manual or automatic, and of the motorised overhead conveyors;

– electrical assembly, control panels and integration of supervision systems to Industry 4.0 requirements;

– start-up and functional testing of the plant, with verification of the process parameters;

– training of the customer's staff on how to operate the plant.

This turnkey approach means the customer does not have to coordinate different suppliers between manufacturing and commissioning: the company that designs and builds the plant is the same one that assembles it, starts it up and supports it in the years that follow.

Assembling a powder coating plant for metal follows a precise sequence, because each stage determines the next.

1. Site survey and factory check. Available space, clear heights, floor load capacity and the electrical, gas and compressed air supply points are surveyed to confirm the designed layout.

2. Assembly of the pre-treatment section. The washing booths or tunnels and their tanks are installed, together with the hydraulic connections and the water treatment unit.

3. Assembly of the spray booth. The walls, the extraction and powder recovery system and the electrostatic application units, manual or automatic, are put together.

4. Assembly of the curing oven. Insulated panels, heat generator and air recirculation ducts are positioned, and the thermal seal is checked.

5. Assembly of the conveying line. The overhead conveyor, manual or motorised, is installed. It links every station and sets the production rate of the plant.

6. Electrical assembly and control panels. Loads are wired, panels are installed along with the systems that supervise and control the process parameters.

7. Start-up and testing. No-load and load trials are run, the washing, application and curing parameters are set, and the finish quality is verified on the first parts.

8. Staff training and handover. The customer receives the technical documentation and training on operation and routine maintenance.

Varco International carries out all these stages with its own technicians, on the plants it designs and builds.

Yes. As well as complete plants, Varco International manufactures individual components for extending and modifying existing painting plants, including plants originally supplied by others.

The most common jobs are:

– adding a new station to the line, for example a second oven or an additional booth, to increase production capacity;

– replacing or rebuilding part of the plant, such as the application unit, the extraction system or the oven heat generator;

– modifying the conveyor to handle parts of a different size or weight from those originally planned;

– upgrading the electrical panels and control systems, to bring an older plant up to Industry 4.0 requirements;

– dismantling and reassembling the plant when it has to be moved to a new factory.

Every job starts with a technical site survey to check the condition of the existing plant, the space and the supply points available, and ends with the start-up and testing of the modified section.