As a global leader in coil coatings and industrial paints, Beckers has built its reputation on quality, innovation, and continuous improvement. Operating in 18 countries and serving customers in around 60 markets worldwide, the company combines more than 160 years of expertise with a strong focus on advancing high-performance coatings technology.
At Beckers Group UK, maintaining consistency throughout manufacturing and quality control processes is essential. One particular area identified for improvement was the fineness-of-grind test, commonly known as the Hegman test - a critical process used within the coatings industry to assess particle dispersion quality.
Traditionally, the test relies heavily on visual interpretation by operators analysing a grind gauge. While widely used across the industry, the process can be affected by human subjectivity, with results varying depending on the individual carrying out the test.
Following an investigation into a grind-check issue during the milling stage of production, the Beckers team recognised that repeatability was an issue. They were experiencing unnecessary re-processing because QC operations were erring on the side of caution. At the other end of the scale, they had taken a batch off the mill ready for production only to discover the quality was not to standard. This led to non-conformities in quality control and required reprocessing, which delayed other jobs in the milling schedule and resulted in unnecessary energy consumption that conflicted with the company’s sustainability goals.
The investigation highlighted the need for a more objective and standardised approach to grind measurement, one capable of improving repeatability. It was critical that reliable readings were obtained at the milling stage of the process.
Finding the right solution
When evaluating automation technologies, Beckers identified Labman’s TIDAS system as the ideal fit for its requirements.
The decision was supported by both previous industry experience with the technology and TIDAS’ growing reputation as a recognised standard within the coatings sector.
The implementation of TIDAS introduced an automated and highly repeatable approach to fineness-of-grind testing. By removing much of the subjectivity associated with manual interpretation, the system immediately improved confidence in the consistency of results.
The benefits have been felt across both production and quality control teams, with the system now used daily at key stages of the manufacturing process.
Unlocking the value of real-time data
In addition to improving repeatability, TIDAS has also transformed how Beckers captures and uses quality control data.
Prior to implementation, the company had limited quantitative data available for analysing grind quality trends. With the automated system now integrated into operations, live measurement data is continuously generated and stored, creating greater visibility across the production process.
Although the system has only been operational for a few months, Beckers is already beginning to see the long-term value of this enhanced data capability.
A recent training exercise highlighted the consistency of the automated process particularly clearly. Seven different technicians tested the same sample using TIDAS, reproducing the same result within just 3µm - demonstrating a level of repeatability difficult to achieve through traditional manual testing methods.
The additional process control is also helping Beckers identify manufacturing issues earlier and more effectively.
A strong collaborative partnership
Alongside the technical benefits of the system itself, Beckers highlighted the importance of Labman’s support throughout the project.
The ongoing responsiveness of the Labman team has also helped ensure a positive implementation experience, with support continuing beyond installation and commissioning.
Looking ahead, Beckers sees further opportunities to collaborate with Labman to explore additional automation and standardisation opportunities across its laboratory and manufacturing processes.
As manufacturers increasingly move towards data-driven quality control, the collaboration between Beckers Group UK and Labman demonstrates how automation can improve repeatability, strengthen process control, and support more consistent product quality across modern manufacturing environments.