A case study in durability, automation, and in-house transformation
Astec Industries is a global leader in manufacturing heavy-duty road building equipment and a wide range of other industrial products. With over 16 brands under its name and a legacy of innovation spanning more than a century, Astec brings together a portfolio of trusted product lines with deep manufacturing roots. To meet the demanding durability requirements of its equipment, Astec invested in a custom industrial powder coating oven and finishing technology from TITAN Catalytic, bringing its coating operations in-house and improving quality control, efficiency, and production flexibility.
Durability isn’t just a bonus; it is an absolute requirement. And with that said, Astec’s machines represent a significant investment for customers, who in return expect long-term durability and minimal maintenance. One compromised component — a chipped coating or corroded part — can lead to rust, failures, downtime, and costly repairs. That’s why the integrity of the powder coating and curing process is mission critical.
Yet until recently, Astec faced significant challenges in maintaining coating quality and turnaround times. Their standard mode of operation by outsourcing their coating process introduced delays, quality inconsistencies, and logistical complications. With over 250 uniquely sized parts in their catalog, shipping components off-site for finishing and re-inspection was inefficient, costly, and just a logistical nightmare for the Production Department.
The Turning Point: Bringing Coating In-House
In 2021, Astec initiated a strategic review of their finishing operations. The question at hand was whether they could regain control and improve both quality and efficiency by bringing the powder and liquid coating processes in-house?
After evaluating the long-term benefits, Astec chose to develop their own internal line. After significant review and expansive vetting, they selected TITAN Catalytic as the partner to provide core oven technology and automation controls, custom-built to meet the exact needs of their operation.
The Solution: Tailored Equipment for Oversized Parts
With a team in place, the next challenge was designing a system capable of handling Astec’s uniquely demanding parts. The parts are not only numerous, but large — many are awkwardly shaped, heavy, and difficult to maneuver. That meant off-the-shelf solutions wouldn’t cut it. TITAN worked closely with Astec to develop a vertically oriented production line, designed to handle the company’s specific geometries and material needs.
TITAN Catalytic installed a custom 12 foot high and 40-foot Pre-Gel InfraRed oven that gels powder quickly and uniformly, before the parts enter the convection curing process. Pre-Gel ovens are critical on a line like this, as the Convection Oven utilizes moving hot air to cure the parts efficiently. This same movement of hot air can unfortunately have a negative impact on the powder on the parts unless it has been partially cured first. Only a light, uniform gel layer is required — precisely what the Pre-Gel IR oven is designed to achieve before parts move into convection curing.
Three section oven without doors during production & interior showing heaters & pedestal during production.
This dual-stage approach (IR gel + convection) enables Astec to optimize energy use by reducing convection time and operating at lower temperatures while still achieving a strong, uniform cure and a high-quality finish.
“TITAN’s IR Oven gave us the flexibility to run a wide range of parts by allowing us to dial in the energy needed to correctly gel powder on parts based on part thickness.From the design phase to post-install support, the TITAN Catalytic team was there every step of the way. Their responsiveness and attention to detail helped us get the system running smoothly and confidently.”
— Chris Hohol, Manufacturing Engineer, Astec Industries
New Control System: Smarter, Safer Operations
Freestanding TITAN Oven Control Panel (Photo 1) & Main Astec Touchscreen Controls Integrated to TITAN Panel (Photo 2)
A key aspect of this project was automation. Therefore, TITAN Catalytic, alongside ETTER Engineering, developed a custom Control Panel System with a Human Machine Interface (HMI). The HMI was installed into the Main Control Panel Cabinet for the entire line; the interface allows the Lead Person to remotely adjust recipes and monitor oven performance in real time from one single location. The lead operator now has full control and can adjust recipes and monitor performance in real time without leaving the control station. This eliminates unnecessary movement along the line, minimizes downtime, and removes the need for operators to enter hot oven zones or halt production for manual adjustments.
Cost Savings and Energy Efficiency
Bringing the line in-house has already delivered significant savings. No more shipping parts off-site, no more delays in inspection or rework, and now Astec has full control over quality — right on their factory floor.
Including the TITAN IR before the Convection Oven gives Astec the ability to experiment with and increase conveyor speed on certain groups of parts, reducing the load on their convection ovens. Thanks to the IR pre-gel stage, less time and lower heat are required downstream. TITAN also provided a red-sheet evaluation for blower motors in the convection ovens, offering other opportunities for optimization.
Results: Total Control, Higher Quality, and Continued Long-Term ROI
Since launching their in-house coating system with TITAN Catalytic’s support, Astec Industries has:
- Reduced costs from fewer outsourced parts, and minimized rework
- Improved quality assurance, with full Q/C handled onsite
- Energy efficiency, with smarter oven zoning, lower temperatures, and recipe control
- Safer work conditions, improved ergonomics through remote-access automation and HMI control
- Enhanced flexibility, enabling the line to accommodate even more part sizes and designs than originally planned with streamlined changes on the fly
By building a fully customized line, Astec ensures that every part — from the largest machine base to the smallest bracket — meets their rigorous quality standards and stands up to the real-world demands of their industry.
About TITAN Catalytic
TITAN Catalytic is a trusted partner for manufacturers who demand superior performance from their finishing systems. From IR ovens to advanced automation and energy-efficient solutions, TITAN helps companies streamline operations and deliver top-tier quality at every stage of production. Learn more about TITAN-Catalytic at: www.titan-catalytic.com.
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