Breaking Down Finishing Department Bottlenecks with Automation

In this episode of The Finishing Touch Podcast from Superfici America, host Bret Johnson takes listeners on a deep dive into one of the most important challenges in finishing departments: bottlenecks. Whether you’re a seasoned industry professional or just starting out, understanding how to spot and solve these bottlenecks can make or break your production line.

Click to view the full episode on YouTube

The Three Big Bottlenecks

Bret highlights the three most common bottlenecks in finishing departments:

1. Sanding

   • Sanding occurs multiple times in the finishing process: whitewood sanding, primer or sealer sanding, and inter-coat sanding.

   • Machines like wide belt sanders, edge/profile sanders, orbitals, planetary heads, and brushing machines automate much of the work.

   • Automation reduces labor injuries, increases throughput, and delivers consistent quality. However, some level of hand sanding is usually still required for detail work.

2. Spraying

   • Automated spraying improves consistency, speeds up production, and reduces rework caused by human error.

   • Automation also cuts down on material costs by improving transfer efficiency.

   • With the ability to handle multiple parts simultaneously and manage frequent color changes, automated sprayers help minimize delays.

3. Drying

   • Drying is often the most frustrating bottleneck—parts sit idle until they are ready for reprocessing.

   • Automated drying solutions, such as laminar ovens, jet air systems, infrared (IR) ovens, stacking ovens, and UV curing, drastically reduce wait times.

   • Even cutting dry time from an hour to 10–15 minutes makes a huge impact on efficiency.

Why Bottlenecks Matter

When one stage of finishing slows down, it impacts the entire production line. Identifying signs such as work-in-progress piling up, idle equipment, or delayed customer delivery helps pinpoint where the issue lies. Bret emphasizes that while solving one bottleneck is helpful, the greatest efficiency comes from eliminating all three.

The Future of Automated Finishing

Historically, many shops invested heavily in CNC machines but left finishing to manual processes. As skilled finishers become harder to find, automation in sanding, spraying, and drying is no longer optional—it’s essential for consistent quality and competitive throughput.

Bret notes:

“Our generation isn't producing as many [finishers] as the previous generation. So I think it's going to be critical that even these small shops start automating in the future.”

This shift is already underway, and shops that embrace automation will be better prepared to meet demand, maintain quality, and reduce their reliance on scarce labor.

Key Takeaways

• Sanding, spraying, and drying are the three major finishing bottlenecks.

• Automation reduces labor costs, improves consistency, and increases efficiency.

• Drying is often the biggest delay, but advanced oven and curing solutions help minimize downtime.

• The best way to determine the right solution is hands-on testing in the lab.

To explore more about automated finishing, visit Superfici America’s website, follow on social media, and subscribe on YouTube for video tutorials.