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Growing demand, limited production capacity, and challenging workpiece dimensions presented Lignatur AG with new challenges in the surface finishing of its timber construction elements. Together with BÜRKLE, the company developed a continuous process solution combining sanding, spray coating, drying, and handling. The result: higher productivity, reproducible coating quality, and a future-proof manufacturing solution to support further growth.
Lignatur AG, headquartered in Waldstatt, Switzerland, is one of the leading suppliers of innovative timber ceiling and roof systems in the German-speaking market. The company develops and manufactures multifunctional structural timber elements that, in addition to their load-bearing function, also meet requirements for sound insulation, fire protection, and room acoustics. The prefabricated ceiling and roof elements are used in schools, sports halls, office buildings, as well as residential and commercial buildings, representing sustainable construction with a high architectural standard.
As demand for its timber construction solutions continued to grow, Lignatur also experienced a steadily increasing need for surface-finished components. Until then, the coating of roof elements measuring up to 16 meters in length and weighing up to two tons had been carried out manually. At the same time, the conventional drying process posed significant challenges to production. After coating, the large-format workpieces had to be stored temporarily, occupying valuable production and storage space while limiting throughput. Lignatur therefore initially searched for a solution to automate the drying process. During joint analyses and application trials, however, it quickly became clear that considering the drying process in isolation would not unlock the full optimization potential.
Instead, the idea emerged to rethink the entire surface finishing process and automate the coating application as well. "Originally, we were simply looking for a solution to automate the drying process of our components. Together with BÜRKLE, we then rethought the entire process. What started as a single task evolved into a fully integrated production concept that intelligently combines sanding, coating, drying, and handling. What impressed us most was that BÜRKLE did not focus on individual machines but understood the entire process chain and developed a complete, well-designed solution. This holistic approach was the key factor behind the success of the project," explains Ruedi Jud, Co-owner and Member of the Board of Directors of Lignatur AG. In addition to BÜRKLE's extensive expertise, its proven references were another decisive factor in selecting the company as a partner.
The implemented system features a direct connection to the upstream production process with a high-frequency press and was designed as a circular production line. Following the automated sanding process, the components are coated in a ROBUSeco spray coating machine. The coated workpieces are then dried using a JET nozzle dryer before undergoing a visual inspection, after which additional coating layers can be applied if required. To reliably handle varying workpiece heights, the spray coating machine was installed on a fully automatic height adjustment system that automatically adapts the machine to the respective workpiece height. In addition, the line control system enables centralized management of all process parameters and direct integration of the sanding machine. Color changes can even be carried out during operation, allowing different coatings to be applied economically within a single component.
Another major advantage lies in the reproducible coating quality. During trials at the BÜRKLE Technology Center, it was already demonstrated that the coating weight could be adjusted precisely and to the exact gram according to the coating manufacturers' specifications. This is particularly important for functional coatings such as fire protection coatings. In daily production, the system's high level of precision ensures consistently high surface quality while providing additional process reliability.
In addition to the technological advantages, Lignatur also benefits organizationally from the integrated solution. The company has therefore established the foundation for further growth and is well positioned to meet the increasing demand for high-quality, surface-finished timber construction elements over the long term. "With the new production line, we have not only expanded our capacity but also taken an important step toward future-proofing our business. The high level of process stability, the precise control of the coating application, and the seamless integration of all production steps create real added value in our daily operations. Looking back, choosing BÜRKLE as a partner was the right decision, as they understand both the technology and the specific requirements of our production and were able to develop a sustainable solution," concludes Jud.
The Lignatur project clearly demonstrates how significant efficiency gains can be achieved through a holistic approach to coating, drying, and material flow. Rather than optimizing just a single process step, BÜRKLE and Lignatur jointly developed an integrated solution that improves productivity, quality, and future readiness alike. For companies facing similar challenges in surface finishing, the project highlights the added value of a fully integrated production concept, particularly when demanding workpiece dimensions, high quality requirements, and individual production conditions must all be accommodated.
