Lab-scale replication of coil coating for process optimization
A lab-scale coil coating replication system utilizing integrated spectrometry and FMEA to identify and mitigate process vulnerabilities, offering a framework for predictive maintenance and defect prevention.
Overview
Landi Industries presents a lab-scale replication of coil coating processes aimed at optimizing production through predictive maintenance and defect prevention. This innovative solution leverages integrated spectrometry and Failure Mode and Effects Analysis (FMEA) to uncover and address process vulnerabilities and inconsistencies. By simulating full-scale production in a controlled, smaller-scale environment, the system enables iterative improvements and a smoother transition to full-scale operations.
Technical specifications
The proposed solution involves a two-phase approach:
- Phase 1: Implementation of an in-line spectroscopic system on an active production line to monitor coating application and curing in real time. This system identifies inconsistencies and defects, enabling immediate intervention without halting production.
- Phase 2: Development of a small-scale pilot line that replicates the full-scale process at reduced speeds. This setup includes sensors, failure detection systems, and PLC integration, allowing for detailed analysis and iterative improvements before scaling up.
Key features:
- Real-time monitoring of coatings via integrated spectrometry
- FMEA to pinpoint and address process vulnerabilities
- Scalable pilot line for controlled simulation and testing
Technology readiness level
Currently at Technology Readiness Level 2, this solution has been conceptualized and validated in a lab environment. The next steps involve refining the pilot line and further validation to progress towards full-scale implementation.
About Landi Industries
Landi Industries is an engineering services firm founded in 2016 that provides comprehensive development across mechanical engineering, electrical engineering, and software development. The company operates using a Modified Agile Hardware Development (MAHD) framework and a Test-Driven Development (TDD) philosophy to integrate design, prototyping, simulation, and manufacturing support. By acting as an outsourced R&D partner, Landi Industries assists clients—ranging from startups to publicly traded companies—in transitioning from initial product concepts through to full-scale, retail-ready production. Their technical capabilities span specialized areas such as high-speed circuit design, firmware development for IoT systems, rapid fabrication, and reverse engineering, all backed by expertise in regulatory standards across industries like medical, automotive, and aerospace.
The firm focuses on bridging the gap between complex engineering solutions and business ROI, helping manufacturing leaders reduce waste and optimize operational costs through data-driven process improvements. By offering services that include end-to-end product lifecycle management, DFM (Design for Manufacturing) consulting, and custom fabrication, they enable clients to de-risk projects and achieve critical milestones. Landi Industries emphasizes technical transparency and strategic collaboration, working closely with product leaders to ensure that architectural decisions are aligned with both market needs and long-term business objectives. Their work has supported a diverse array of applications, including specialized thermal management, water sterilization technology, and consumer wearable devices.
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