AI that lowers powder cost, protects quality, and removes the guesswork
СoatingAI turns coating data and process expertise into clear, repeatable actions — helping every line, recipe, and shift perform more like your best.
Trusted by leading manufacturers
Purpose-built AI, proven on live coating lines and designed to work with the equipment and production teams you already have.
Fast, Low-Disruption Deployment
Set up and train in about four hours per line, with minimal impact on production.
Guaranteed Powder Savings
Achieve at least 10% powder savings, with typical results of 16% or more.
Clear AI-Guided Actions
Give operators and maintenance teams specific actions while keeping people in control of the process.
One AI platform.
Every coating line in view.
CoatingAI connects line, recipe, thickness, powder-use, and equipment data in one system. Its AI learns how each process performs, identifies waste and drift, recommends the right action, and verifies improvement across shifts, lines, and sites.
From AI-guided optimization to autonomous coating control.
Start with AI recommendations, add real-time thickness feedback, and move toward self-adjusting process control as your operation is ready.
How coatingAI works
One continuous AI-driven loop turns coating data into clear actions, repeatable performance, and measurable results.
Connect the Process
Bring together recipe settings, gun output, thickness measurements, powder use, production results, and equipment-condition data.
Let AI Learn What Drives Performance
CoatingAI combines production data, physics-based models, and coating expertise to understand how each line, powder, recipe, and gun behaves.
Act on Clear Recommendations
Operators, engineers, and maintenance teams receive precise settings, checks, and priorities—not another dashboard they have to interpret.
Prove and Protect the Improvement
Track powder savings, coating quality, process consistency, and equipment health. Verify what improved and prevent performance from gradually drifting back.
AI built for high-volume coating operations
For industrial manufacturers and contract coaters where powder cost, coating quality, and repeatable line performance directly affect margin and throughput.
Office and Commercial Furniture
Protect finish quality across colors and product families while keeping material use under control.
Material Handling Equipment
Standardize coating performance across high-volume lines and demanding industrial parts.
Heavy Equipment and Machinery
Reduce powder cost and variation across large parts, complex geometries, recipes, lines, and shifts.
Appliances and Metal Products
Improve first-pass consistency while reducing overapplication, rework, and rejects.
Contract Coating and Finishing
Adapt more consistently across customers, powders, colors, part types, and frequent production changes.
AI proven in real coating operations
See how manufacturers and contract coaters use coatingAI to lower powder costs, protect quality, and make their best coating performance repeatable.
Video stories
Hear directly from coating industry leaders using coatingAI to improve performance across their operations.
Surtech Industries, Inc.
Terry Spisak
President
Maas Brothers, Inc.
Kevin Maas
President
The Finishing Company, Inc.
Joe Smith
General Manager
Measured impact, in their own words
Read how coating teams are reducing powder use, improving consistency, and maintaining measurable results over time.
As someone who’s worked with powder coaters for over 30 years, I’ve never come across a tool as effective as BluePrint OS. It’s become my go-to solution for clients looking to optimize their coating lines. With minimal disruption, we’ve seen immediate improvements — powder savings of up to 10% and a significant reduction in rejection and rework. BluePrint OS has taken the guesswork out of the process, allowing coaters to focus on quality and efficiency.
After 25 years in the coating industry, I’ve seen plenty of tools come and go, but BluePrint OS is a game-changer. It cut our powder waste by 12% in just two weeks, and the fine-tuning features have minimized rework and rejects across the board. The implementation was seamless, with almost zero production downtime. I can confidently say this system delivers real, measurable results.
We’re delighted to team up with coatingAI and strengthen our technical service capabilities. We proactively look for ways to support customers in becoming more sustainable in their operations and this will significantly improve our ability to help them get better results — while contributing to our own ambition of halving carbon emissions across the value chain by 2030.
Let’s Get Your Coating Project Started
Tell us a little about your project, and our team will help you find the right coating solution for your needs.