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True closed-loop control is only possible when regulation is based on the measured coating build on the part — not on assumptions about transfer efficiency. By capturing coating thickness immediately after application and integrating with any system via Flex-Apps, coatmaster Flex enables the first robust, outcome-based control loop for industrial coating lines.

[Winterthur, Switzerland] – You kept asking for a closed-loop solution. With coatmaster, it’s finally possible.

One year ago, only three coating lines worldwide were operating with a closed-loop solution powered by coatmaster technology. Today, more than fifty-five production lines run with automated, intelligent coating control — a clear sign that the industry is ready for the next generation of process optimization.

What has driven this development is a consistent message from coatmaster’s partners and customers:

“We want a true closed-loop system — one that keeps coating thickness constant, automatically and in real time.”

With coatmaster Flex OS V7, that vision becomes reality. The new operating system brings together non-contact coating thickness measurement, advanced connectivity, and integrated AI tools to make outcome-based coating regulation accessible for every production line.

Why closed-loop must be based on measurement at the part

Transfer efficiency is never constant — it changes with gun settings, electrostatics, geometry, and environmental conditions. Regulating the process upstream at the spray gun cannot compensate for these fluctuations.

Only a measurement taken directly after powder application provides a reliable basis for process control.

By using this value as the control variable, coatmaster Flex allows the coating line to adjust itself automatically, stabilizing film build regardless of external influences.

A new generation of coating control

FlexOS V7 introduces Flex-Apps — modular, customizable software components that run directly on coatmaster Flex. They enable system manufacturers and end users to create tailored control logic, connect seamlessly to any PLC or fieldbus system, and automate powder output adjustments in real time.

Combined with built-in AI analytics, the system continuously learns from process data and supports predictive, adaptive optimization — ensuring consistent quality, reduced material consumption, and maximum process stability.

Real-world applications powered by OS V7

The versatility of OS V7 is already being demonstrated through close collaboration with partners across the coating industry:

MS (Binks) has integrated OS V7 into its Close-Loop with the MS Remote Control solution, enabling real-time process feedback and fully automated powder output adjustment.

coatingAI has developed Blueprint+, an intelligent application connected to OS V7 that uses AI-based process modeling to guide operators toward optimal coating parameters and consistent film quality.

And this is just the beginning. Further collaborations are underway with partners including Erzinger in Brazil, Parker Ionics in Japan, Syntema i Arbrå in Sweden, and Electron in Turkey — each working to extend closed-loop coating control into new markets and production environments around the world.

Prof. Dr. Nils Reinke, Co-Founder and Co-Sales Director at coatmaster AG, added:

“With OS V7 we’re not simply launching a version — it’s a platform that brings our customers and partners the ability to embed intelligence, connectivity, and automation directly into their coating lines. By making closed-loop control and AI-driven optimisation part of the standard, we’re unlocking new possibilities — empowering our distributors and integrators worldwide to not only measure, but truly master the coating process.”

Oliver Lengweiler, Head of R&D, stated:

“Our R&D team worked closely with partners across industries to create an Operating System that reflects their real production challenges. OS V7 gives them the freedom to design their own solutions.”

coatmaster FlexOS V7 will be available starting November 30th, 2025. Existing coatmaster Flex systems can be upgraded to the new version via a software update, providing access to all new features, including Flex-Apps for closed-loop control and integrated AI support.

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