When a watchmaker designs precision gears for a watch, every component must harmonize seamlessly—a perfect blend of art, science, and accuracy. It’s quite similar when creating the perfect shade for paint and coatings. It requires creative finesse to capture the desired hue and meticulous precision to ensure consistent results across batches. Often, it’s a manual process, requiring two to five days and repeated iterations for the perfect results, locking up valuable production capacity and challenging operational efficiency.
Despite advancements in digital tools, many batch manufacturing facilities remain reliant on traditional manual processes—from recipe tracking to color matching—which are time-intensive and prone to variability. However, digitization and the right artificial intelligence (AI)-based applications can fundamentally transform this process, making it faster, more accurate, and dependably repeatable.
Let’s explore how digitalization is reshaping the paints and coatings industry.
Addressing the color-matching conundrum
Color matching is a critical process across diverse industries, from automotive and aerospace to fashion and packaging. Color ensures brand consistency in consumer goods, provides flawless finishes in construction materials, and delivers precise hues in cosmetics and textiles. The demand for accurate and dependable color reproduction highlights its vital role in aesthetics and functionality.
This need also translates to the paints and color industry, where achieving consistent color is no small feat. Traditionally, when creating a new paint batch, operators follow product recipes. Any slight change in raw materials, ingredients, or processing time has an impact, so each batch requires very accurate quality control where operators:
- Take samples
- Transport them to quality labs
- Await test results that guide optimum pigment adjustments
According to the paint grade, this cycle might repeat two to five times per batch, consuming up to two hours per iteration.
Fortunately, there are solutions that, combined with internet of things (IoT) controllers and I/O modules, are changing the game. These tools reduce iterations and testing times by capturing historical trial-and-error data and generating precise pigment adjustment recommendations, directing the tinter expert on the fastest path to reach the target color.
AI-powered color-matching technology has been shown to cut time-to-market, unlock production capacity, and produce consistent results.* These innovations can improve color accuracy, boost productivity, and enhance customer satisfaction.
Leveraging AI for smarter operations
AI can play a pivotal role in optimizing batch manufacturing by learning from historical data, and AI-driven solutions can:
- Track operational data rigorously to identify inefficiencies
- Recommend optimal formulations based on past results
- Enable real-time adjustments that minimize waste and improve quality
For example, a paint facility using AI-powered solutions reported 30–50% efficiency gains in batch preparation.* This level of improvement stems from reduced iterations and optimized use of raw materials. Such advancements underscore the transformative potential of integrating AI with traditional manufacturing methods.
Realizing the benefits of AI-driven batch management
While color consistency is a primary focus, the benefits of AI-driven batch management extend further:
- Energy optimization: AI-based systems monitor energy consumption in real time, offering actionable insights to reduce waste and align operations with sustainability goals.
- Raw material savings: Facilities can reduce the excess use of pigments and other costly ingredients by minimizing trial-and-error adjustments.
- Knowledge retention: Digitized processes ensure that operational knowledge is captured and preserved, reducing reliance on individual expertise and making operations more resilient to workforce changes.
This innovative approach adds to Schneider Electric’s capabilities in the Paints and Coatings industry, where ProLeiT software, a trusted batch management and recipe tracking solution, has provided a strong portfolio of digital tools for years. Manufacturers can gain precise insights and automation capabilities that elevate their production processes, ensuring consistent color matching and greater efficiency and sustainability across all operations.
Embracing the future of paints and coatings
The shift toward digital transformation in paints and coatings is not just about operational efficiency—it’s about unlocking new possibilities. With Schneider Electric™ innovations and proven tools, manufacturers can accelerate production, improve quality, and stay competitive in a rapidly evolving market. As sustainability and innovation become central priorities, digitization and AI will shape the industry’s future.
Transform your paint production today with Schneider Electric’s ProLeiT solutions, and discover how AI-driven tools can help you achieve greater precision, efficiency, and sustainability. Contact us to discover the possibilities.
*Based on Schneider Electric’s internal customer data
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