Tadano’s challenge: Less waste, higher efficiency
Tadano faced multiple challenges with their liquid coating processes, primarily due to the complex nature of their crane bodies and the harsh environments in which they operate. Cranes require durable, scratchresistant coatings, yet the increasing demand for visual appeal and high-quality finishes added a new layer of complexity. Tadano's vehicles are custom-painted in unique colors, with over 300 color variations applied annually, leading to a reliance on manual labor by skilled workers.
Additionally, many vehicles are painted post-assembly, requiring efficient and even coverage on complex, deep, or hard-to-reach surfaces. With their previous liquid coating equipment, Tadano had applied excessive layer thickness to ensure coating quality, which resulted in high paint consumption. Tadano’s goal was to update the coating process in order to enhance efficiency and reduce material waste.
New liquid coating system boosts Tadano’s performance
WAGNER proposed the installation of 39 Puma 28-40 high-pressure piston pumps paired with 39 GM 5000EAC manual electrostatic guns, using the ACF 5000SP nozzle for excellent atomization. This solution proved to be most efficient, after Tadano had also made performance comparison tests with other competing manufacturers.
The GM 5000EAC gun is very flexible and easy to operate: The user can quickly switch between three voltage settings - high, medium, and low - directly on the gun, without interrupting the coating process. The automatic voltage adjustment function that adjusts the voltage according to the distance from the workpiece was also attractive for Tadano.
For smaller parts, the voltage can be set steplessly (5-80 kV), which prevents excessive layer thickness and enables Tadano to coat workpieces of all shapes and sizes in a highly efficient way. “The reduced overspray and better coating quality have minimized rework and allow us to coat complex areas more efficiently”, says Masaaki Sueura, Production Assistant Manager at Tadano.
Since the installation of the WAGNER liquid coating equipment, Tadano was able to reduce the required layer thickness and paint consumption by approximately 20% while significantly improving coating quality. Another benefit of the electrostatic gun is its serviceability, i.e. the extremely small number of parts, which means that Tadano can replace parts on site, minimizing delays in production.
The Puma 28-40 high-pressure piston pumps contribute to the efficiency of the system: The air motor with the special IceBreaker technology prevents ice formation and ensures consistently high performance in all working conditions. The pumps operate with particularly low pulsation even at low working pressures.
In addition to the technical advantages, WAGNER’s overall service has been a standout feature for Tadano, with prompt responses and seamless support throughout the implementation and operational phases. “From the lab test to the introduction of the system, we felt that WAGNER was very accommodating and worked with us to solve the problems, which made the process go smoothly. We were able to quickly resolve issues that arose during the study process by communicating with the head office in Germany”, states Kai Shimizu, Production Engineer at Tadano. “The after-sales service is also as responsive as we had hoped for, and we can use the equipment with peace of mind thanks to the prompt on-site visits.”
The new liquid coating system has brought measurable improvements to Tadano's production process: Enhanced coating efficiency while also reducing paint consumption and waste. The flexibility and reduced need for rework have streamlined the company’s processes and ensure high-quality results even on complex crane bodies.
