For electronics manufacturers across South Asia, upgrading from manual or semi-automated conformal coating to a fully integrated inline solution is one of the most impactful steps toward consistent product quality and higher throughput. This case study documents how an electronics manufacturer in India evaluated, selected, and successfully deployed Sanco’s conformal coating machine solution — from initial requirement assessment through on-site commissioning and handover.
Customer Background
| Item | Details |
|---|---|
| Location | India |
| Industry | Electronics manufacturing — PCB assembly and conformal coating |
| Challenge | Existing process could not meet precision requirements for new PCB designs; coating inconsistency and material waste were increasing production costs |
| Goal | A complete inline conformal coating solution — precise, automated, scalable, and easy for operators to run |
Solution Selected: Four-Axials Conformal Coating Machine
After reviewing the customer’s PCB types, coating material, production volume, and factory layout, Sanco’s engineering team proposed the Four-Axials Coating Machine as the core solution. The customer evaluated this against alternative options and selected it based on three key factors: the additional rotation axis for complex-path boards, the advanced film spray valve technology, and Sanco’s full-service support model covering installation, commissioning, training, and ongoing after-sales.
Why the Four-Axials Machine Was the Right Fit
| Customer Requirement | How the Solution Addressed It |
|---|---|
| Complex-path PCBs with angled surfaces | X / Y / Z + rotation axis — valve reaches any angle without repositioning the board |
| Reduce coating material waste | BF-028 Film Spray Valve — up to 99% material transfer efficiency, near-zero overspray |
| Sharp, consistent coating boundaries | Film valve delivers superior edge definition — no splash, no blur, no manual touch-up |
| Fast product changeover for high-mix production | Teaching programming with Sanco software — operators switch programs quickly at the machine |
| Inline integration with existing SMT line | SMEMA interface — connects directly with conveyors, loaders, and curing ovens |
Coating Valve Configuration
The BF-028 Film Spray Valve was selected as the primary coating valve for this project. Sanco offers a full range of coating valves to suit different materials and process requirements — the right valve for each application is determined during the pre-sales engineering review.
| Valve | Type | Best Application |
|---|---|---|
| BF-028 Film Spray Valve ✔ | Film coating | Ultra-thin uniform coating, precision edge definition, minimal overspray |
| SF-073 Sector Spray Valve | Fan / sector spray | Wide-area coverage on large flat boards |
| G-300HP High Pressure Valve | High pressure spray | High-viscosity materials requiring strong atomization |
| G-500HP Diaphragm Valve | Diaphragm spray | Reliable on/off control, broad material compatibility |
| G-420A Precision Striker Valve | Precision needle | Fine dot and line coating in tight component areas |
| LF-001 Conical Spray Valve | Conical spray | Deep recesses and hard-to-reach geometries |
On-Site Installation & Commissioning
Sanco’s engineering team handled the complete on-site process: equipment installation, line integration, coating path programming for the customer’s full board range, and hands-on operator training covering daily operation, parameter adjustment, and routine maintenance. The line was commissioned and handed over within the agreed schedule.
Delivery Results
| Before | After Sanco Solution |
|---|---|
| High material waste from overspray | Up to 99% material transfer efficiency — significantly lower coating cost per board |
| Inconsistent edge quality, manual touch-up required | Sharp, repeatable coating boundaries — touch-up eliminated |
| Cannot coat complex-path or angled board areas | Four-axis motion covers all surface angles and geometries |
| Slow changeover, operator-dependent results | Stored programs, fast switching, consistent output regardless of operator |
24/7 Online Engineer Support: Sanco provides round-the-clock online engineering support after every delivery. Our technical team is available 24 hours a day to assist with process questions, parameter adjustments, and troubleshooting — ensuring your production line stays running with minimal downtime.
Related Conformal Coating Line Solutions
Depending on your PCB type, production volume, and floor layout, Sanco offers several ready-designed coating line configurations:
- Double-Side Online PCBA Conformal Coating Line Solution
- Double-Side Online PCBA Conformal Coating Line Solution 2
- Online PCBA Conformal Coating Line with Return Plate
- Online PCBA Conformal Coating Line with Return Plate 2
- Compact and Economic Double-Sides Coating Line
For production lines that also require dispensing, potting, or curing processes, our inline dispensing machines, potting machines, and curing ovens can be integrated into the same line. Contact our engineering team to discuss your project.
