Why the old system had reached its limit
Before the upgrade, Motala Hissar was running an aging powder system with a steel booth. High powder waste and limited automation were major problems, and frequent color changes added further challenges. The new system needed to deliver highly efficient coating of elevator parts, lower powder consumption, and fast, reliable color changes.
WAGNER’s PXS powder center combined with the Flowsense technology stood out as the most advanced automatic solution. The new line was installed in summer 2025.
Smart powder management with PXS and Flowsense
Motala Hissar chose an S-Line powder system with an S-Cube booth. This booth model offers maximum flexibility and is designed for demanding applications with a high automation level. A perfect match for large elevator components. Eight PEA-X1 automatic guns apply the powder with high precision. A manual workstation adds flexibility for pre- or post-touchups on especially complex parts.
The compact PXS powder center manages powder preparation, supply and fast color changes. The complete system control is integrated into the cabinet. With the WICOS control and operating system, Motala Hissar can monitor the whole system performance in detail. The Data Hub interface of the PXS additionally provides raw process data for deeper production analysis.
Flowsense is integrated into the PXS. This innovative technology automatically measures and regulates the powder quantity: Each feeding element has built-in sensors that measure the output in grams per minute. The system automatically adjusts the powder flow to the target value and corrects deviations. The result: constant coating thicknesses and less powder consumption.
With Flowsense, Motala Hissar can now see exactly how much powder is being used. Coating thicknesses stay consistent from batch to batch, making quality more predictable. The technology pays off directly: Powder consumption has been reduced by 15-20% compared to the previous system.
Another benefit is maintenance transparency: The status of each injector is clearly displayed on the touchscreen in a traffic light system. Necessary wear part replacements are automatically recommended only when truly necessary, which means that Motala Hissar can extend the service life of the nozzles and reduce operating costs. In fact, with the previous system, they had to replace nozzles once per month – now, thanks to Flowsense, the system is running up to 4-5 months with the same nozzles.
Cutting energy use with the EEP
Like all WAGNER powder systems, the new line at Motala Hissar is equipped with the Energy Efficiency Package (EEP): The flow-optimized design of the monocyclone reduces pressure losses, allowing the final filter to run with a smaller fan motor. This has reduced energy consumption by 15-20%.
The specially shaped pipes reduce powder deposits and wear and improve the powder recovery - a small detail with big long-term impact. With Flowsense and the EEP, the new system significantly reduces powder waste. This has a positive impact on the environment, as generally 5-6% CO2 emissions can be saved per 1 kg powder.
Conclusion: A high-efficiency line that delivers
Motala Hissar’s new powder coating system brings together speed, precision, and sustainability in a way their old setup simply couldn’t. Large elevator parts and frequent color changes can now be handled with ease. The PXS powder center with Flowsense gives the team full control over powder usage and delivers reproducible, high-quality surfaces. The Energy Efficiency Package reduces energy consumption and boosts recovery performance. It’s easy to see that the upgrade has been a major strategic step forward for the company.
