Production downtime is often caused by a combination of wear and corrosion. The right coating solutions and preventive maintenance ensure continuity of production.
A single instance of production downtime can result in significant costs through lost output, additional maintenance actions and delivery delays. In practice, the cost can quickly rise to tens of thousands of euros per hour. Downtime becomes particularly expensive when it is unplanned. In such situations, urgent response is required: the right workforce, spare parts and solutions are needed quickly, which almost always means higher costs.
Operational reliability does not arise by chance. It is built on anticipation, correct material choices and ensuring that coating solutions are designed as part of the process rather than as a separate step. When stress mechanisms are understood and properly taken into account, wear can be controlled, corrosion slowed and unplanned downtime minimised.
Where do production downtime actually originate?
In real industrial environments, downtime is rarely caused by a single factor. Almost always, it is the result of a combination of several stress mechanisms, such as:
- In mining: wear + moisture + chemicals (equipment, pipelines, conveyors)
- In metal processing: high temperatures and chemically aggressive environments
- In the forest industry: rollers and pulp equipment where pitch, resin and chemicals change friction and loading
Problems often begin unnoticed. Coating adhesion weakens, the coating detaches and material is carried into the final product. Quality decreases or a batch is rejected, and in the worst case, a safety risk arises
The most common root cause is corrosion beneath the coating. A correctly selected and applied coating can last for years or even decades depending on the application, so an unusually short service life almost always indicates incorrect material selection or underestimated stress.
Is the hardest coating the solution to production downtime?
In industry, it is surprisingly common to assume that the harder the coating, the longer the service life. In practice, the reality is more complex.
- Hardness alone does not determine performance
- An overly hard coating may be brittle and prone to cracking
- Mechanical properties such as toughness and adhesion are equally critical
In addition, the application determines whether low friction is required for improved cleanability or higher friction for process control. The optimal coating solution is always based on the actual operating environment, not on a single property.
Recent material developments have introduced hybrid materials, nanostructured coatings and multilayer systems that combine wear resistance, corrosion resistance and controlled friction characteristics. At the same time, tightening regulations are driving the industry towards safer and more precisely controlled solutions. This enables the selection of coatings that are not only hard but durable as a whole — and truly optimised for the process.
Foresight separates controlled production from constant reaction
In most processes, it is well known where problems tend to recur. The challenge is not a lack of information, but that stress is not always analysed with sufficient precision. When critical components are evaluated based on actual operating conditions and coating solutions are updated accordingly, maintenance can be scheduled during planned shutdowns.
When it is not realistic to move components, on-site coating provides an effective alternative: downtime is significantly reduced, risks decrease and total costs remain under control. Many process industry operators benefit from having the situation assessed by an external expert. This is particularly important when ensuring that material selections and coating solutions are truly aligned with operating conditions. During Fincoat’s on-site audits, processes are reviewed directly at the customer’s facility, enabling an accurate understanding of real conditions and the identification of concrete improvement areas.
Ultimately, it comes down to systematic choices. When coating solutions are integrated into the process, service life increases, downtime decreases and maintenance becomes predictable.
Would you like to ensure that your critical components can withstand real operating conditions?
Contact us and we will assess together how wear and corrosion can be managed more effectively.
Sami Suomalainen
+358 40 762 6289
sami.suomalainen@fincoat.fi
Sami Suomalainen (M.Sc., Materials Engineering) is one of the founders of Fincoat and has been part of the company since its early years. His work focuses on solving customers’ technical challenges in demanding industrial environments. Experience across industries, especially emerging industrial segments, brings continuous learning and the opportunity to develop new, practical solutions. In addition to technical expertise, Sami values collaboration and working closely with people.