Mol Cy's Journey of Growth and Innovation in Surface Treatment
At the end of World War II, there were many military vehicles in the country that were no longer in use, at least not in their current state. Mol Cy, a family business founded in 1944 in Staden, gave these vehicles a second life. After engine overhauls, axle modifications, and other necessary adjustments, they could still be used as bulldozers—ideal tools for the reconstruction of the country.
More than seventy years later, the world has changed significantly, but the company’s focus on the transport industry has remained. Dieter Degrendele, an engineer and quality manager at Mol Cy, explains:
“Today, we have four main product groups: trailers, special trucks, refuse collection vehicles, and we also handle some outsourcing with ITK. Active product development, an innovative approach, and internationalization have made the company what it is today: a group of 400 passionate employees and a market leader in the sector. The secret to our success? Always tackling technical challenges head-on.”
Everything In-House
With a strong desire to grow in customer-related activities, Mol Cy tightly controls its production. “We do everything in-house, from engineering to welded structures, from sheet metal processing to painting. This is essential to maintain flexibility for the customer while always pursuing the highest quality standards,” says Degrendele. This philosophy has served the company well. Mol Cy has seen tremendous revenue growth in recent years. As a result, its painting capacity started to reach its limits. Mol Cy made the decision three years ago to invest in a new installation to replace the old one. However, it was a complex issue due to space limitations in the production hall, combined with the desired capacity, stricter environmental requirements, and the quality standards Mol Cy is known for.
New Installation
Fortunately, Mol Cy knew they could turn to us for their new spray booths, as specialists in the design, production, and realization of installations for liquid coating applications and surface treatment. Commercial director Filip Vandekerckhove handled the project from A to Z. Mr. Degrendele notes, “Right away, we felt that the cultures of both companies aligned. Just as we think alongside our customers, Filip listened carefully to our needs and presented a customized solution. The flexibility, persistence, and knowledge that Sima provided were crucial factors in this story. It was truly a technical achievement to perfectly solve the puzzle. A puzzle we could already see taking shape before the first stone was laid. Using 3D glasses, we virtually explored the new spray booths to discover the outcome.”
Shorter Booths Offer Many Benefits
Mol Cy had four spray booths of 18 meters and two booths of 12 meters, which had proven their worth for nearly 40 years. Now it was time for new technologies focused on energy recovery (frequency-controlled extraction, recirculation, etc.) and operator comfort (better lighting, improved extraction, etc.). On our advice, there are now four booths of 14 meters, one of 18 meters, one of 20 meters, and a separate sanding booth, all located exactly where the previous infrastructure stood. “The benefits of working with shorter booths aren’t only related to energy savings, as less energy is needed for the ventilation systems. It has also led to the construction of a larger mixing room directly behind the spray booth. This means we’re now switching to bulk refills, which is a huge plus in terms of logistics and cost,” says Degrendele with satisfaction.
In each of the six spray booths, as well as in the sanding booth, two three-dimensional lift platforms ensure that all corners of the spray booth are accessible. Attached to the two side walls by guides, these HEX3 pneumatic platforms can move in all directions, allowing the operator to perform their work efficiently and ergonomically.
Quality and Sustainability are Essential
The paint dispensers are built into the platform cage to promote ergonomic work. This also allows for the use of hoses just 7 meters long, reducing solvent consumption. “We’ve implemented a stricter standard to meet environmental regulations. Additionally, the shorter hose length ensures much more effective cleaning than if we didn’t have this lift functionality. We also opted for semi-vertical extraction on the two side panels instead of floor extraction. This, too, was on Sima’s advice—less excavation, lower costs, and consistently optimal spray performance. This was music to our ears because we refuse to compromise on quality,” emphasizes Degrendele. Therefore, management was also crucial for the construction company. “By introducing spray programs, we aim to ensure continuity in the quality of the spraying process. The operator used to turn on his gun and start working. Now, for example, the airflow will already be adjusted based on the next vehicle to be treated in the booth. This way, we also use less electricity and gas and have less paint waste, as sustainability is at the heart of this story.”
Progressive Installation
Another innovation is the use of multilayer films instead of strip paint. “The advantages this offers in terms of booth maintenance are enormous. Contaminated parts can easily be removed, reducing booth cleaning time from an entire day to just half an hour, making it ready for the next job.” Finally, there was the challenge of installing the new spray booths. Mol Cy couldn’t afford production downtime. We, therefore, planned and executed the work in phases, ensuring that four spray booths were always available. “Planning maintenance is not easy, let alone a replacement project where, for several months, we only had two-thirds of our capacity. The timing couldn’t have been better due to the impact of the COVID-19 pandemic. We are extremely grateful for the efforts of Sima, who provided the necessary support during the construction vacation, allowing us to return to full speed as quickly as possible.”