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Automated Paint Systems For Heavy Industry

When production volumes increase and coating specifications tighten, manual painting becomes a bottleneck. A painting robot eliminates the inconsistencies that come with manual application and replaces them with repeatable precision at industrial throughput rates.

At Ventherm, we have more than 40 years of experience delivering paint facilities and robotic solutions for heavy industry. We provide three robotic painting systems, each built around ABB ATEX-rated paint robots combined with Inropa™ self-programming software and Beckhoff PLC control.

Catalogue

Why automate your paint application?

  • A single micron of deviation in layer thickness can compromise corrosion resistance or trigger rework. Manual application introduces variables that are difficult to control, from operator fatigue to shifting ambient conditions.
  • Our robotic painting systems follow programmed paths with sub-millimetre accuracy at precisely controlled speeds and pressures. The Inropa™ PoseFitter generates an optimised robot program for each workpiece automatically, based on 3D scanning and CAD matching.
  • The software runs on more than 25 installations worldwide, generating over 90,000 robot programs per day. From documented projects, our robotic solutions have delivered up to 32% coating material savings and can be operated by 1-2 operators per shift.

PLC control and data logging

  • All three systems share the same control and monitoring platform. The Beckhoff PLC runs a central CPU with decentral I/Os connected via Ethernet/IP, and the safety system follows EN 60204-1.

Remote access and traceability

  • You operate the system through a touch panel, Ventherm’s own app or your PC. Remote access enables our technicians to troubleshoot and service the system without an on-site visit.
  • Our Datahub collects up to 8,000 data points per project, including surface roughness, layer thickness, paint flow and curing parameters. An integrated video system records each painting operation with part number and timestamp for full traceability.
Vetherm Paint and sandblasting robot solutions

Three robotic painting system architectures

Your facility layout, part geometry and production volume determine which architecture is the right match. We offer three configurations.

Gantry systems

Gantry configurations suspend the robot from an overhead X-Y-Z framework, creating a large work envelope without consuming floor space. The configuration is well suited for large cast steel components, wind turbine parts and industrial tanks.

  • High-strength steel frame with precision linear guides and rack-and-pinion drives
  • ABB IRB 5500 or 5510 six-axis ATEX paint robot with up to 22 metres X-axis traverse
  • Servo motors with high-resolution encoders for real-time position feedback
  • ATEX 2G certified below the robot
  • 3D scanning with PoseFitter generates the robot program in approximately five minutes
  • Can operate across two adjacent booths with independent zone ventilation
Catalogue

Floor-driven robots

Floor-driven systems mount a spray painting robot on a rail-guided steel wagon that moves alongside the workpiece at ground level. This configuration is developed for large cylindrical structures such as offshore transition pieces with diameters between 7.5 and 9.5 metres.

  • 5-metre external X-axis extends reach to structures up to 30 metres long and 10 metres in diameter
  • Encoder timing belt for accurate positioning along the full travel distance
  • Paints in 5–6 metre strokes, then the wagon advances and repeats
  • Handles PU, epoxy and glass flake coatings
  • 25–35% paint savings compared to manual application
  • 3D Time of Flight scanner adapts each program via the PoseFitter
  • Approximately 98% automatic surface coverage from documented projects

A full coating cycle for a transition piece typically takes 100-130 minutes

In Line Robots

In Line Robots are the most compact configuration for continuous conveyor-based production. Two ABB IRB 5500 robots are positioned on each side of the conveyor for simultaneous coating. Each robot runs on a vertical lifting axis controlled as a 7th axis, and Inropa™ SteelPainter software handles the full programming cycle.

  • Eight 3D scanners, four per side, measure each workpiece in a dedicated scanning cabin
  • Two programs are generated per workpiece and transferred directly to the robots
  • Conveyor speed optimised per traverse within 0.4-2 m/min
  • Paints H-beams, I-beams and rectangular beams as standard. Add-on options extend to L-beams, T-beams, U-beams, welded profiles and lattice rafters

Ventherm Catalouge

Would you like more information? Please read the Ventherm catalog to view product designs, the company’s benefits, and specifications for use and installation.

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Catalogue 2023

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Katalog 2023

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How do you get started with the right automated paint system?

The right choice depends on your part geometry, production type and facility layout. Each of the three architectures is designed for a specific production environment, from batch-based large components to continuous conveyor lines.

All systems are delivered as complete Plug-and-Paint solutions with ABB robot, Inropa™ software, Beckhoff PLC, CE approval, factory acceptance test (FAT), site acceptance test (SAT) and on-site operator training.

Contact us for a non-binding conversation about which automated paint system fits your production.

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Frequently Asked Questions

Ventherm’s automated paint systems combine ABB ATEX-rated paint robots, Inropa’s self-programming software, and Beckhoff PLC control to eliminate the inconsistencies of manual painting. The robot follows programmed paths with sub-millimetre accuracy, precisely controlling speed and pressure, and the whole system is delivered as a complete “Plug-and-Paint” solution including on-site operator training.

The Inropa PoseFitter software generates an optimized robot program for each workpiece automatically, based on 3D scanning combined with CAD matching, so parts don’t need to be manually programmed one by one. The software is proven at scale, running on more than 25 installations worldwide and generating over 90,000 robot programs per day.

Documented projects show coating material savings of up to 32%, with floor-driven systems specifically achieving 25-35% paint savings compared to manual application and around 98% automatic surface coverage.

Ventherm offers three configurations. Gantry systems use an overhead X-Y-Z framework with up to 22 metres of X-axis traverse, suited to cast steel, wind turbine parts, and industrial tanks, and can operate across two adjacent booths. Floor-driven robots run on a rail-guided wagon with a 5-metre external X-axis, ideal for large cylindrical structures (7.5-9.5 metre diameters) up to 30 metres long and 10 metres in diameter, handling PU, epoxy, and glass flake coatings. In-line robots are the most compact option, using two ABB IRB 5500 robots and eight 3D scanners on a continuous conveyor line, for beams such as H, I, rectangular, and optionally L, T, or U profiles.

For gantry systems, 3D scanning with PoseFitter generates the robot program in roughly five minutes. For floor-driven systems, a typical full cycle for a transition piece runs about 100-130 minutes, and in-line systems run at an optimized conveyor speed of 0.4-2 m/min depending on the part.

The system logs up to 8,000 data points per project, including surface roughness, layer thickness, and paint flow, and records video of each operation tagged with part number and timestamp. Remote access also lets technicians troubleshoot issues without an on-site visit.

The systems can typically be operated by just 1-2 operators per shift, using a touch panel, mobile app, or PC. They’re ATEX-rated (ATEX 2G for gantry systems), CE approved, follow the EN 60204-1 safety standard, and are delivered with factory and site acceptance testing (FAT/SAT).

They’re used across wind power, offshore, defense, railways, agriculture, and general machine industry. Pricing depends on the system architecture and your specific requirements, so it isn’t listed online, you can request a quote via the contact form, by email at info@ventherm.dk, or by phone at +45 62 63 18 68 (Mon-Thu 7:00-16:00, Fri 7:00-13:30).