Over the summer of 2025, the production lines at Syncro System’s Cassola factory shut down for a few weeks longer than the normal holidays to permit planned maintenance work. In this period, the paint plant was completely renewed, taking the company closer than ever to it objectives in terms of quality, efficiency and sustainability in production.

The new plant, which is technologically far more advanced than the old one, came online in recent days and has immediately resulted in a significant improvement in the appearance of painted products.

Two other improvements were made to the Cassola site during the same period: the exterior of the factory was completely painted and a new canopy roof was added on the south side, capable of accommodating up to 10 large vans.

This complex modernisation project has resulted in:

• a new part washing tunnel to complete the first stage of the process of preparing metal parts for painting
• replacement of the powder paint application booths that perform the central stage of the painting process, which uses electrical charges to attach a powder film to metal parts
• computerisation and integration of the painting process into the company’s ERP system.

The paint curing oven and the part drying oven remain unchanged.

One of the sections renovated is the washing tunnel which now performs a rinsing phase using demineralised water. This step ensures more thorough cleaning of parts, resulting in better paint adhesion, greater corrosion resistance and fewer defects such as bubbles and drips.

The old paint plant had two paint booths, one for beige and one for blue. These two single-colour booths have been replaced by a modern multi-colour booth that can apply whatever colour is needed. Colour changes are rapid and fully automated and paint application is more uniform, free of cosmetic defects and has a far lower incidence of over-painted or under-painted areas thanks to a range of advanced technical solutions. Operators can enter a series of parameters for each part and recall them as needed to ensure consistent results and a top-quality finish over time.

Compared to the previous paint plant, the new one guarantees significantly higher productivity and corresponding energy savings. In addition, 99% of the paint is used, meaning a bare minimum of waste. Since Syncro only uses powder paints that are 100% solvent-free, the result is zero harmful emissions to the atmosphere.

The new paint plant is fully computerised and is connected to and integrated into the company computer network. Parameters and processes are digitised and energy efficiency is guaranteed, making the structure fully compliant with Industry 4.0 and 5.0 regulations.