Custom Turnkey Solutions
We take pride in not only the quality of our product, but the service we provide after the equipment is installed; we’ll pick up the phone! Because we design and manufacture our thermal spray equipment, we are uniquely positioned to integrate our systems into customers specific applications.
Thermach is the predominant industry option for custom thermal spray solutions. Why? Simple. We're not your competitor. Your other options are competitors. They coat, we don't. We only supply thermal spray equipment and parts. Proceed with confidence working with our team to create a custom system that meets your exacting specs.
We not only manufacture high quality thermal spray equipment and spare parts, we also design and develop full turnkey solutions.​
Explore our comprehensive turnkey solutions, designed to meet the unique needs of your industry and application. From noise enclosures to robotic manipulation and efficient dust collection, we will work with you to develop a solution that is crafted to your specific application. Our automated solutions integrate seamlessly, boosting productivity and safety on your production floor.
Applications & Industries
We have experience installing thermal spray equipment in a variety of industries, including aerospace, medical, oil & gas and power generation to name a few. Whether looking to replace an aging line, add more capacity or just bringing thermal spray in for the first time, we can help.
Turnkey System Technical Capabilities & Design Standards
Thermach designs and integrates complete thermal spray cells, coordinating mechanical, electrical, controls, and safety systems into a single, fully supported solution. All subsystems are engineered to function as one cohesive system.
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Integrated subsystems may include:​
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Thermal spray equipment
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Robotics or gantry motion
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Part manipulation
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Enclosures and booths
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Dust collection
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Controls and safety systems
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Capabilities
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6-axis industrial robots
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7th-axis linear tracks
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Rotary positioners and custom part manipulators
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Multi-torch
Integration Focus
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Torch and hose management
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Recipe-based motion programs
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Minimize operator dependence
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Capabilities
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Single- or multi-axis gantry systems
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Long-part & large-structure coating applications
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Shipyard, pipe, and heavy-industry solutions
Design Considerations
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Structural stiffness and vibration control
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Travel length, speed, and acceleration
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Environmental protection for spray environments
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Maintenance access and serviceability
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Capabilities
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Rotary turntables and positioners
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Headstock / tailstock lathes
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Servo-driven rotational axes
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Custom fixturing and part supports
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Design Considerations
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Part weight, balance, and center of rotation
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Required rotational speed and torque
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Coating access and line-of-sight optimization
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Integration with robot or gantry motion
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Thermal exposure and environmental protection
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Typical Applications
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Shaft, roll, and cylindrical components
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Tube mill and pipe coating applications
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Symmetric or indexed coating patterns
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Continuous or indexed rotation during spraying
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​Controls & Integration
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Coordinated motion with robot or gantry systems
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Servo or VFD-driven rotation (application dependent)
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Recipe-based speed and position control
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Safety-rated integration with the overall cell
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Capabilities
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Full spray booths
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Partial or modular enclosures
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Overhead crane or track entry/exit
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Typical Features
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Steel or composite panel construction
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Acoustic attenuation designed to meet OSHA exposure limits
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Integrated lighting and viewing windows
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Access doors with safety interlocks
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Overspray containment and airflow management
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System Types
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Dedicated cell collectors
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Centralized collection systems
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Compliance Focus
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Designed to support OSHA, NFPA, and local environmental requirements​​
Design Criteria
​Design Criteria​
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Airflow sized to the specific thermal spray process
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Hood and ducting optimized for capture efficiency
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Spark arresting and fire mitigation options
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Maintenance access
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Controls Scope
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PLC-based system control
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HMI operator interface
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Recipe and parameter management
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System alarms and fault handling
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Interface with customer plant systems (as required)
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Integration Points
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Thermal spray power supplies
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Robot controllers
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Dust collection systems
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Safety devices and networks
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Safety Architecture
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Safety controlled by Allen-Bradley Safety PLC​
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One integrated safety system governs the entire cell
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Safety circuits from all subsystems are tied together to create a seamless, unified system
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Standard Safety Features
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Non-contact door interlocks
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Emergency stops as determined by cell design and risk assessment
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Hydrogen detection in booth (when hydrogen is used as a process gas)
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​Process Control & Interlocks
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Dust collector interlocks with spray process
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Pyrometer integration
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Process parameter monitoring
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System alarms and fault notifications​
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Integrated Subsystems May Include:
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Robotics
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Dust collection
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Part manipulation
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Enclosures and access doors
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Thermal spray process equipment
Safety Communication
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Hardwired safety circuits
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CIP Safety over Ethernet/IP (application dependent)
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Optional Safety & Monitoring Systems
Not all features are applicable to every system
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Dust collection airflow switches
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Vibration sensors
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Flame detection
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Oxygen detection
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Thermach Provides:
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Application review and concept development
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Complete system design and documentation
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Factory Acceptance Testing (FAT)
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Installation, commissioning, and training
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Ongoing service and technical support
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