Join us at Fabtech 2024, October 15-17, 2024. We will be at the Total Finishing booth, W2648.

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Stop Wasting Powder.
Reduce Touch Ups.
Eliminate Rejects.

Get guaranteed savings with Blueprint OS—your all-in-one solution to reduce costs, improve quality, and streamline your coating line.

Minimal Disruption

15-minute implementation while you run production.

Simple Implementation

Easy setup and quick optimization.

10% Powder Savings

Guaranteed to reduce waste and cut costs.

ROI in Days

Flexible payment terms to get monthly ROI within just a few days of implementation.

They Trust Us

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Introducing Blueprint™ OS

So, Why Blueprint OS?

Let’s face it—running a coating line without optimization is like driving a car without ever checking the engine. You might get by, but you’re leaving performance, savings, and precision on the table.

That’s Where Blueprint OS Comes In.

Blueprint OS is like your “digital blueprint” that fine-tunes every element of your coating system—spray patterns, reciprocator settings, and more—guaranteeing optimal performance and powder savings. Think of it as your secret weapon to keeping your line running at peak efficiency with minimal effort.

The Secret To Unlocking A Perfect Coating Process

It’s the difference between production lines that waste powder and produce rejects and those that consistently deliver flawless, uniform coatings.

Without Blueprint OS

  • Inefficiency from manual adjustments.
  • Guesswork in process settings.
  • Uneven coatings leading to rejects.
  • Tribal knowledge running the show.

With Blueprint OS

  • Precision-adjusted process settings.
  • Perfect Calibration for every powder.
  • Maximized efficiency with reduced powder usage.
  • Guaranteed powder savings and reduced rework.

Ready To Ditch The Guesswork And Level Up Your Coating Process?

Get a Free Health Check Consultation and see how you save at least 10% in powder usage.

Start your journey with Blueprint OS today!

What Is Blueprint OS?

Blueprint OS is all the following in one consise system

Blueprint™ OS is

Your Coating System HealthCheck

You’re focused on running production, and when issues arise, the quick fix is often just turning up the powder. But what about the problems your eyes can’t see?

With Blueprint™ OS HealthCheck, you can…

  • Take 10 minutes to assess the current state of wear and tear on booth components.
  • Gain clarity to adjust process parameters to the current state of your line.
  • Clearly identify out-of-range parts, so you know what needs fixing before it impacts production.
HealthCheck replaces:

trial and error, tribal knowledge

Schedule Your Onsite Demo Today

Blueprint™ OS is

Your Powder Equalization Tool

Consistency is key, but no two guns spray the same without proper equalization. Guesswork in settings results in inefficiencies and wasted powder.

With Blueprint™ OS Powder Equalization, you can…

  • Equalize your guns for uniform powder distribution across all parts.
  • Instantly detect discrepancies in gun outputs and correct them.
  • Optimize your powder usage to minimize waste and maximize coating efficiency.
Powder Equalization replaces:
Powder Equalization replaces:

Manual adjustments, wasted powder

Start Optimizing Today

Blueprint™ OS is

Your Spray Calibration System

All powders spray differently.  The reciprocator settings defined at installation might be set for a completely different powder behavior than what you see now. With spray patterns varying for each powder, one-size-fits-all doesn’t cut it.

With Blueprint™ OS Spray Calibration, you can…

  • Calibrate each gun to its optimal spray pattern based on your top-used powders.
  • Tailor reciprocator settings to ensure uniformity across every part.
  • Say goodbye to striping and uneven coatings.
Spray Calibration replaces:

Inconsistent spray patterns, manual adjustments

Book Your Calibration Today

Blueprint™ OS is

Your Closed Loop Optimization System

Keeping things running smoothly requires ongoing adjustments, but making them manually is a time-sink. Automate the process for consistent performance.

With Blueprint™ OS Closed Loop Optimization, you can…

  • Measure and adjust for target thickness on every powder batch, in real-time.
  • Automatically fine-tune each gun’s output without manual intervention.
  • Ensure consistent, optimized coating thickness across the board.
Closed Loop Optimization replaces:

Manual tweaking, inefficient powder usage

Get Started With Closed Loop Optimization

Blueprint™ OS is

Your Fine Tuning Module

Wear and tear happen, but constant monitoring and adjustments keep your line performing at its peak. A little fine-tuning goes a long way.

With Blueprint™ OS Fine Tuning, you can…

  • Perform quick weekly checks to stay close to optimal performance.
  • Make small, targeted adjustments to ensure your line’s efficiency.
  • Minimize process interruptions to less than 15 minutes per week.
Fine Tuning replaces:

Frequent downtime, inefficient processes

Keep Your Line Tuned

Blueprint™ OS is

Your Predictive Maintenance Solution

Parts break, but with the right insights, you can see it coming. Avoid costly downtime and be prepared with proactive maintenance.

With Blueprint™ OS Predictive Maintenance, you can…

  • Track wear and tear across all critical components.
  • Get early warnings for parts likely to fail, so you can replace them ahead of time.
  • Avoid unexpected shutdowns by ensuring you always have the right parts on hand.
Predictive Maintenance replaces:

Unexpected downtime, emergency part replacements

Upgrade to Predictive Maintenance Today

Testimonials

“We’re delighted to team up with coatingAI and strengthen our technical service capabilities. We proactively look for ways to support customers in becoming more sustainable in their operations and this will significantly improve our ability to help them get better results – while contributing to our own ambition of halving carbon emissions across the value chain by 2030.”

Surtech

Terry Spisak - President

Surtech Industries, Inc.

Maas Brothers

Kevin Maas, President

Mass Brothers, Inc.

The Finishing Company

Joe Smith, General Manager

The Finishing Company, Inc.

Schedule Your Onsite Demo Today

Testimonials

…

Listen to what our customers say

Maas Brothers

Kevin Maas, President

Mass Brothers, Inc.

The Finishing Company

Joe Smith, General Manager

The Finishing Company, Inc.

Surtech

Terry Spisak - President

Surtech Industries, Inc.

What the industry is saying about coatingAI and Blueprint OS

Coatmaster AG

Nils Reinke
Chief Executive Officer

We’ve integrated BluePrint OS with our Coatmaster technology to bring real-time optimization to the coating industry. The precision and efficiency of BluePrint OS are unmatched, allowing powder coaters to reduce waste, improve quality, and streamline their processes. Together, we’re helping companies achieve significant cost savings and enhanced performance with minimal disruption to production. It’s a true game-changer for the industry, and I’m excited to be part of this journey.

Combined Finishing, Inc.

Jeff Cummins -
Co-Founder and Partner

I’ve worked in the industry for nearly 30 years.  I’ve never come across a tool like Blueprint OS. It’s become my go-to solution for clients looking to optimize their coating lines and helps me provide more value to the client. BlueprintOS has taken the guesswork out of the process, allowing coaters to focus on quality and efficiency.

MWN
Pulverbeschichtungs GmbH

Achim Weiss -
Operations Manager

With coatingAI, we can prevent striping on surfaces, resulting in a more homogeneous coating. The software allows us to handle complex coating adjustments much better and faster, improving both the quality and efficiency of the process. We’ve reduced human error and created a more consistent coating process, ultimately saving powder and improving overall performance.

Schedule Your Onsite Demo Today

FAQ

With BluePrint OS, the production impact is minimal. We’ve designed the system to require less than 15 minutes of process interruption per week. You’ll get maximum benefits, including optimized gun settings and minimized powder waste, with minimal downtime and no disruption to your production flow. It’s a seamless integration that keeps your line running smoothly while delivering improved results.
No, BluePrint OS simplifies the process. You don’t have to calibrate for every color or size. The system allows you to calibrate your top-used powders, and from those, it extrapolates settings for other colors. Even if you use a wide range of powders, BluePrint OS ensures your system stays optimized across the board without the need for constant recalibration.
You’ll start seeing results almost immediately. BluePrint OS is designed to deliver fast ROI, with many clients experiencing significant powder savings and improved line efficiency within just a few days of implementation. You can expect up to 10% powder savings and reduced rejects and rework soon after integrating the system into your production process.

Comprehensive support every step of the way. coatingAI provides continuous support after implementation to ensure your line runs optimally. This includes ongoing fine-tuning, performance tracking, and predictive maintenance features that help you stay ahead of any potential issues. Our team is always available to assist with questions, system adjustments, and any new calibrations required as your line evolves.

Blueprint OS continuously monitors and fine-tunes your gun outputs to ensure uniform powder distribution across all parts. It automatically detects discrepancies in gun spray and adjusts the settings to achieve optimal powder usage, eliminating the overuse of powder and reducing waste significantly. This leads to an immediate savings of up to 10% in powder consumption.

Blueprint OS customizes reciprocator settings based on the specific behavior of each powder you use. Since every powder has unique characteristics, the system analyzes your spray patterns and optimizes reciprocator movements to ensure efficient and uniform coatings for all powder types, reducing defects like striping and uneven coating thickness.

Yes, Blueprint OS includes a built-in health check and predictive maintenance feature. It regularly assesses the wear and tear of your booth components, notifying you when parts are out of range or nearing the end of their lifecycle. This early warning system prevents unexpected downtime and ensures your line remains operational without disruptions.

Blueprint OS performs precise calibrations on spray patterns, powder output, and reciprocator movements. It ensures that each gun is set to its optimal performance level, tailored to the specific powders you use. This reduces inconsistencies and ensures uniform coating across all parts, improving overall product quality while reducing rejects and rework.

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