WAGNER Energy Efficiency Package: Up to 40% Less Energy Consumption in Powder Coating Systems
Date: June 2025
Introduction
The increasing energy prices and the demand for more sustainable production processes make energy efficiency a critical consideration for anyone operating powder coating systems. J. Wagner GmbH offers a compelling solution with its Energy Efficiency Package (EEP), integrated into all WAGNER powder coating systems featuring a cyclone.
The energy consumption in powder coating systems is largely driven by cabin suction, the suction hose, and the recovery system. The final filter's fan motor, which can reach over 30 kW depending on the system size, plays a crucial role. The EEP, developed by WAGNER several years ago, addresses this by incorporating special air guides and optimized components that significantly reduce energy requirements.
Reduced Resistance, More Power
The core of the EEP concept is the specially developed monocyclone. It separates the powder-air mixture, directs the exhaust air to the final filter, and returns the powder to the guns. Its flow-optimized design results in significantly lower pressure losses compared to conventional systems. Consequently, the final filter requires a smaller fan motor, leading to energy consumption reductions of up to 40% without compromising suction performance.
The optimized monocyclone also enhances powder recovery. Separation efficiency increases by one to two percentage points, allowing for more powder to be recovered and saved. The specially shaped hose between the cabin and the monocyclone further minimizes system pressure loss. Its unique design, differing from conventional market solutions, significantly reduces powder deposits and wear, protecting the powder, improving recovery quality, and ensuring a stable and clean color change process. Typically, manual cleaning of the monocyclone's interior during color changes is no longer necessary, shortening the process.
Diagram Description: The document includes diagrams illustrating the EEP system, showing the guided airflow in the monocyclone and the final filter unit with EEP. Another diagram compares the optimized tubing (left) with standard market solutions (right), highlighting reduced powder deposits and wear.
Further Savings with EEP Plus
For even greater system efficiency, the optional EEP Plus package can be selected. This system automatically detects when there are no suspended components on the conveyor (so-called hanging gaps) and switches to ECO mode. In this mode, the fan motor operates at a reduced speed, further lowering energy consumption. As soon as components are detected again, the system automatically resumes normal operation. Depending on the production process, this can save an additional 10% to 30% of energy, without any intervention from the operating personnel.
Diagram Description: A graph illustrates the motor speed during operation with the optional EEP Plus. It shows the fan motor reducing speed during hanging gaps (ECO mode) and resuming normal speed when components are present again, demonstrating energy savings during powder coating.
This technology pays for itself. With the Energy Efficiency package and the optional EEP Plus, WAGNER offers a state-of-the-art solution for highly energy-efficient powder coating. For system operators, this translates into a clear economic advantage: lower energy consumption significantly and sustainably reduces current operating costs without compromising process reliability or coating quality.
More Information
For more information, visit: WAGNER Energy Efficiency Package
Contact
Contact Person: Elias Sick
Portfolio Manager Powder
Email: elias.sick@wagner-group.com
About WAGNER
J. Wagner GmbH, located in Markdorf, Germany, is part of the WAGNER group of companies under the umbrella of Wagner International AG, headquartered in Altstätten, Switzerland. WAGNER is a leading global manufacturer of equipment and systems for coating surfaces with powder, liquid paints, and other liquid materials. Founded in 1947, WAGNER has consistently set quality standards and offers industrial companies, trade businesses, and DIY enthusiasts economical, reliable, and user-friendly solutions characterized by high quality and advanced technology. The WAGNER Group is represented worldwide by approximately 2,000 employees in 20 operating companies and around 400 agencies. The WAGNER Group is owned by the Josef Wagner Foundations, which exclusively pursue non-profit and charitable objectives.
