Coatmaster AG Intelligent Coating Control System Enables Real-Time Line Optimization
Coatmaster introduces Flex OS V7, an operating system for closed-loop coating control with AI-driven analytics and modular Flex-Apps for industrial applications.
Coatmaster Flex OS V7 system. Source | coatmaster AG
True closed-loop control is only possible when regulation is based on the measured coating build on the part — not on assumptions about transfer efficiency. By capturing coating thickness immediately after application and integrating with any system via Flex-Apps, coatmaster AG’s (Winterthur, Switzerland) Flex OS V7 system enables a robust, outcome-based control loop for industrial coating lines. The operating system brings together noncontact coating thickness measurement, advanced connectivity and integrated AI tools.
Transfer efficiency is never constant — it changes with gun settings, electrostatics, geometry and environmental conditions. Regulating the process upstream at the spray gun cannot compensate for these fluctuations. Only a measurement taken directly after powder application provides a reliable basis for process control. By using this value as the control variable, Coatmaster Flex allows the coating line to adjust itself automatically, stabilizing film build regardless of external influences.
Flex OS V7 introduces Flex-Apps — modular, customizable software components that run directly on Coatmaster Flex. They enable system manufacturers and end users to create tailored control logic, connect seamlessly to any PLC or fieldbus system, and automate powder output adjustments in real time. Combined with built-in AI analytics, the system continuously learns from process data and supports predictive, adaptive optimization — promoting consistent quality, reduced material consumption and improved process stability.
The versatility of OS V7 is already being demonstrated through close collaboration with partners across the coating industry. MS (Binks) has integrated OS V7 into its Close-Loop with the MS Remote Control solution, enabling real-time process feedback and fully automated powder output adjustment. CoatingAI has developed Blueprint+, an intelligent application connected to OS V7 that uses AI-based process modeling to guide operators toward optimal coating parameters and consistent film quality. Further collaborations are underway with partners including Erzinger in Brazil, Parker Ionics in Japan, Syntema i Arbrå in Sweden and Electron in Turkey.
“Our R&D team worked closely with partners across industries to create an operating system that reflects their real production challenges,” says Oliver Lengweiler, head of R&D, coatmaster AG. “OS V7 gives them the freedom to design their own solutions.”
Coatmaster Flex OS V7 is now available. Existing Coatmaster Flex systems can be upgraded to the new version via a software update, providing access to all new features, including Flex-Apps for closed-loop control and integrated AI support.
