Above: Taking a closer look at material selection, like this powder coating, can help users optimize costs.
September, 2025- Dynamic tariffs, fluctuating demand and labor scarcity are creating uncertainty for OEMs, fabricators, job shops and others. With this uncertainty comes a hesitancy to make longterm plans. This period of wait-and-see can frustrate decision makers, but it can also represent an opportunity to look inward to identify areas where operational efficiencies may lead to higher profits.
One key opportunity for efficiency is the finishing line. “While finishing may seem like a minuscule portion of your operation, small changes in this area can have a significant impact on overall profitability,” says Michael Click, technical service representative for Sherwin-Williams General Industrial. Within the finishing line, several factors can help boost the bottom line, including material selection, process flow and personnel training.
MATERIAL SELECTION
“Choosing the right coatings to fit your needs and processes can be one of the most effective ways to reduce total applied costs,” says Click. However, he warns against always choosing the lowest cost option. “The savings you get from a cheaper price per gallon (or pound) will likely be offset by increased application time, paint usage and rework,” advises Click.
Coatings with higher solids content typically deliver better coverage and first-pass yield, which can streamline application. “If energy or gas bills are driving costs up, there are lowcure formulas that can reduce oven temperatures while maintaining cure speed,” he notes.
ONECURE
Advanced formulas are meant to achieve greater operational efficiencies. “We offer wet-on-wet and dry-on-dry formulas, which cure the primer and topcoat together,” says Click. The OneCure powder coating from Cleveland-based Sherwin-Williams allows for a dry primer and dry topcoat to be applied and then cured simultaneously.
Initially developed for the trailer industry, then implemented for agriculture and large construction equipment coatings, “OneCure creates a stronger bond between the primer and topcoat layers, which strengthens performance and enhances corrosion resistance,” says Click. Eliminating the need for a bake cycle between the primer and topcoat also helps speed up the coating process, optimize floor space, lower energy costs and reduce lead times.
Proper training of personnel, especially in the pretreat area, is one way to increase efficiency.
DURASPAR IP
Another factor to consider for increased efficiency is mil thickness, which starts at 0.001 in.). Sherwin-Williams developed Duraspar Industrial Performance (IP) initially for the transportation sector to enhance first-pass coverage and minimize rework. “Duraspar IP has the rugged performance of an industrial coating, while requiring a lower mil thickness than most competitors. It can help users reduce overall paint process time, material usage and lower total applied cost,” Click explains.
Each supplier provides a recommended mil thickness, specifying how much of the coating should be applied to achieve optimal performance. “Some are lower, meaning you’ll use less paint.” He points out that although formulas typically di er by only a few millimeters, the savings can quickly add up, depending on part sizes and throughput. Click stresses the importance of measuring mil thickness regularly “to help ensure you’re not over-applying and wasting product.”
Duraspar IP was developed with convenience in mind. “Duraspar IP is extremely easy to apply―even for new painters― which can shrink the learning curve and training time for new operators,” adds Click.
A line audit can suggest ways to improve workflow for better efficiencies.
TOTAL APPLIED COST
“Material prices are important but they’re just one piece of the puzzle,” according to Click, citing hidden costs and inefficiencies that are not always reflected in budgets, like excess energy usage, rework, process inconsistencies, lengthy cure times and waste. “These factors can significantly impact profitability. However, once identified, they also offer real opportunities to improve.”
Calculating total applied costs and uncovering hidden issues isn’t always straightforward. It takes a deep understanding of coatings technology, application techniques and workflow efficiency to identify areas for improvement.
Part of Click’s role at Sherwin-Williams is performing line audits for customers, providing insights to greater efficiencies. “Typically, we start by getting to know your business, then reviewing the basics of your finishing operation as they relate to your standards, goals and existing processes. We ask a series of qualifying questions that drive us to an understanding of what areas we should focus on.”
MATERIAL HANDLING
Details uncovered during a line audit can add up to huge gains in productivity. Click recalls one customer whose original finishing process took 69 hours per unit. Sixty of those hours were dedicated to material handling. The paint crew was working 12-hour days, bringing parts to and from various shops to get blasted, sanded, taped and finally painted. This customer knew the finishing process could be more efficient but did not know where to start.
The Sherwin-Williams team recommended a solution that eliminated the need for multiple locations, cutting 60 hours from the process. “The new formula also cured faster, reducing oven times by 50 percent and lowering energy costs. These changes allowed the customer to reduce finishing time from 69 hours to just five hours. It completely changed the customer’s production output, tripling the number of units finished in the same amount of time―in turn, tripling the potential revenue,” notes Click.
Labor can often be the biggest line item in the finishing operations.
OPTIMIZING PERSONNEL
Labor is often the biggest expense of a finishing operation and, with skilled workers in short supply, maximizing your team’s efficiency is crucial, notes Click. This starts with an optimal workflow.
During a line audit, Click advises that the paint department be set up to work linearly and continuously, meaning parts should follow an efficient pathway from pretreatment all the way to racking. “Any line stops or color gaps on a conveyor system will add operational costs, no matter how small. And if parts are zigzagging all over your facility, your team is wasting a lot of time and energy shuing back and forth,” adds Click.
He also emphasizes the importance of proper training. “There are a lot of steps to a finishing process, each requiring specific knowledge and know-how. If one thing is missed, your bottom line will suffer. Training on pretreatment is critical.
“All coatings will fail if parts aren’t properly cleaned,” Click continues. “Equipment maintenance is also crucial. [Paint spray] guns should be cleaned daily to maintain peak performance. Worn or clogged equipment will not only waste paint, but lengthen application time, cause quality issues and create unnecessary rework.” Implementing improvements to a finishing line doesn’t have to become a massive effort in order to achieve a substantial impact. “By focusing on material selection, process efficiency and optimizing flow, you can reduce costs and set up a solid foundation for growth when market conditions stabilize,” says Click.
Sherwin-Williams General Industrial, 800/800-1900, industrial.Sherwin-Williams.com.
