Oxworks – Gema Automatic Powder Coating System Supply & Installation

10 Nov, 25

Oxworks – Gema Automatic Powder Coating System Supply & Installation

Client Profile

Oxworks is a national manufacturer and supplier of aluminium, glass, and steel fencing, screening, and balustrade systems. With a 9,500 sqm state-of-the-art manufacturing facility in Crestmead, Brisbane, and 16 distribution centres across Australia, Oxworks services both residential and commercial markets from DIY to major developments. https://www.oxworks.com.au/

Project Overview

In January 2025, Oxworks partnered with Ryonex to supply and install a complete Gema Automatic Powder Coating System to address rising production costs and quality concerns. The investment included advanced automation, powder management, and bespoke booth design. This system was implemented to reduce powder waste, improve surface finish consistency, lower labour costs, and enhance compliance with new powder coating standards. https://www.gemapowdercoating.com/en/

ARTICLE CATEGORY

The Challenge

Oxworks faced increasing production costs related to powder, energy, and labour, particularly in their powder coating operations. Surface finish quality needed to be flawless, but frequent reworks and high levels of powder contamination were driving inefficiency and waste. With the 2025 revision of AS 3715 standards looming, maintaining regulatory compliance became a pressing concern. The team also needed to reduce reliance on operator skill to standardise performance and minimise downtime between colour changes.

Our Solution

Ryonex delivered a fully integrated Gema Automatic Powder Coating System tailored to Oxworks’ production line layout. The solution included:

  • Two OptiFlex GM04 manual guns
  • 14 Optospray CG22-CP gun controls
  • A central OptiCentre OC06 powder management system with auto functionality
  • GEMA Magic Control 4.0 for precision coating control
  • Dual-axis vertical and horizontal reciprocators (ZA07-13 and XT10)
  • A bespoke RMCS spray booth and multicolour mono cyclone

This system enabled faster colour changes, reduced powder waste, and allowed consistent, high-quality finishes across all coated products. Automation significantly lowered the impact of operator variability and improved the work environment by reducing overspray and waste.

Implementation Highlights

  • Project delivered: January 2025
  • Location: Crestmead, Brisbane
  • Custom-designed booth integrated into existing line
  • Full training and support provided for system handover
  • Immediate efficiency gains and operator satisfaction

The Results

  • Surface finish quality improved by 100%
  • Reworks eliminated entirely (zero reported)
  • Powder waste reduced from 100–200kg/day to just 10–15kg/day
  • Colour change times reduced to 8–9 minutes
  • Estimated annual savings of AUD $300,000+ in powder, labour, and productivity
  • Investment payback achieved in 2 years
  • Enhanced operator workflow and workplace safety

Oxworks reported significant improvements in product consistency, operator satisfaction,
and sustainability outcomes.

Key Benefits Delivered

2 -year ROI achieved
90%+ powder waste reduction
Zero reworks post-install
8–9 min colour change time
Automated gun control & dosing