Polyurea Spray Line Case Study

Case Study: Polyurea Spray Line



Customer, Challenge & Risks:

Pioneer Industrial Systems was approached by a service provider for the oil and gas industry. We were contacted by their general manager. They approached Pioneer Industrial Systems after researching automation and robotic companies that specialize in spraying various materials.


The customer needed to produce a large amount of coated mat on an automated production line.  Pioneer was tasked with applying the material on a moving mat line. Currently, they were doing this by hand.  Quality and the volume of material required were quickly becoming an issue.  Finding reliable labor to work in a manual spray booth in the Texas heat was also a major challenge.


The customer would be faced with losing orders if they could not automate this process in the upcoming months.



The customer found Pioneer Industrial Systems through the FANUC Robotics Integrator website.  Pioneer fit their need for an automation provider specializing in various spray materials using robotics.  The reached out to our sales staff via our website.  Our sales team went to work uncovering their needs and working together on the required specifications.  A visit to their production facility helped to understand the current method of hand spraying and the challenges that lie ahead.


Using Fanuc’s 3D simulation software, Pioneer was able to identify a Fanuc robot that would meet the payload and reach requirements for this system. A proposal was submitted, and the customer submitted their Capital Project Approval Request to their corporate management and a purchase order was issued to Pioneer.


The equipment had to be fast, accurate, and reliable to guarantee 100% material coverage at the thickness required.  Pioneer proposed using line tracking to adjust speed of the robot and the material output based on the matt line speed.  Fanuc’s Dual Check Safety (DCS) package was installed in the robot to reduce the safety distance requirements around the robot cell by defining protective DCS zones around the working robot envelope. Robot travel outside these safety zones creates an immediate stop.


Pioneer then designed and built a drying oven and conveyor after the spray booth to meet their drying requirements.


Upon customer approval of all project mechanical and electrical design drawings, the material was ordered, and the build began on Pioneer’s shop floor. Once the cell assembly was completed, the customer came to Pioneer for an onsite one-day runoff. After customer approval on the runoff, the machine was disassembled, shipped, and Pioneer’s assembly crew went on-site to install the equipment.


The customer was provided support documents including machine drawings, a detailed machine manual, the latest copies of the robot programs, and a spare parts list.



Outcomes of Success:

The customer replaced a manual spray operation with repetitive motions and strenuous working conditions with a fully automated spray and drying system, where the operator became more of a machine tender than the one performing the manual labor.  The safety was drastically improved by removing the operator from a spray-born, dirty environment.  Efficiency, output, and quality were all greatly improved.



This case study is available for download in a PDF format!

This PDF includes more details, photographs, video links, and a technical product data-sheet. Email sales@pis.us and ask for your copy of the “Polyurea Spray Line Case Study” today!