As is often the case when something new is created, this story also began with an unusual enquiry. Robatech South Africa was contacted by EnviroWrap, a company that produces surface protection materials. They had developed a new material that is melted in a manner similar to hot melt adhesive and is then applied in a liquid state. It cures quickly and can subsequently be peeled off without leaving any residue and be recycled. EnviroWrap approached us with the question of whether this material could be applied using a Robatech adhesive application system.
As Managing Director of Robatech South Africa, it was immediately clear to me that this was an interesting innovation. So we set out to test this material with our application systems. Fortunately, EnviroWrap – the material shares the same name as the company – actually behaves just like a hot melt adhesive. This means it can be easily melted using a conventional adhesive melter and applied with our application heads. The key question was therefore not whether the material could be processed, but:
EnviroWrap: EnviroWrap: A sustainable alternative to plastic wrap Nachhaltige Alternative zu Schutzfolie
Compared to conventional protective films, EnviroWrap is solvent-free and emits no VOCs. This makes it inherently more environmentally friendly than lacquers or adhesive films. EnviroWrap is applied in a thin layer, so less material is used overall than with adhesive films. After use, EnviroWrap can be recycled—it is simply remelted and can thus be reused up to six times.
The requirement was clear: EnviroWrap was to be applied across all surfaces requiring protection, such as profiles, windows, or refrigerators. So we set to work at Robatech South Africa, testing and experimenting—in close collaboration with the Project Sales Team at our headquarters in Switzerland ((link to PST blog)). The Project Sales Team (PST) is Robatech’s team for custom applications that go beyond standard solutions. Without this team, this project would likely have ended here. After all, innovative solutions require not only technical expertise but also practical experience and a well-equipped application center.
We deliberately chose a spray application because it allows even complex or three-dimensional components to be coated evenly. Using the Aero spray head as a starting point, we determined the application parameters through countless tests: this included the application temperature, which determines the material’s viscosity, as well as the correct application volume, spray distance, type of spray nozzle, spray air pressure, and, last but not least, the arrangement and number of spray heads.
Industrial spray application for peelable protective coatings
The only thing missing from the overall solution was a system capable of applying EnviroWrap on an industrial scale. Since this was a completely new application, no machine manufacturer had ever built anything like it before. So, in 2023, I promptly founded the company RPS Automation together with my colleague Franso Groenewald, with the goal of developing custom-made machines for applying EnviroWrap. RPS Automation closely collaborates with EnviroWrap and Robatech. It was only through the combination of material, suitable application technology, and process expertise that a complete solution for industrial surface protection was created – one that had never before existed on the market.
Although the technology is still in its early stages, we have already successfully implemented our first systems. Several systems are currently in use in the United States – including for the protection of aluminum profiles and windows during production, transport, and installation.
In the early applications, individual small Aero spray heads were used, each tailored to the specific task. For larger surfaces, such as American-style refrigerators, the Project Sales Team developed an arrangement featuring multiple spray heads whose spray patterns overlap to create a continuous, uniform coating. This allowed us to coat even large and irregular surfaces evenly.
For applications on large components – such as windows or profiles – the spray head is also integrated into a robotic system. This allows even complex geometries to be coated automatically and with consistent quality.
Robot-assisted spray application of EnviroWrap
After several years of development work, we have now reached a point where the interplay of material, application, and machinery has proven itself in practice. The potential of this technology is particularly evident in the construction industry: building components are often exposed to a wide variety of conditions over long periods of time, yet must still arrive at the customer’s site in perfect condition. The peelable protective coating offers an alternative to traditional films here – especially because it can be easily removed even after a long period of time and leaves no residue behind.
At the same time, the technology opens up possibilities beyond these applications. It could be used in any situation where sensitive surfaces need to be temporarily protected, such as for high-quality components or in the automotive industry – for example, to protect wheel rims until final delivery.
And to me, this development clearly demonstrates that innovation doesn’t happen in isolation, but through close collaboration. What we’ve achieved – EnviroWrap, Robatech, and RPS Automation – we’ve achieved together. And I’m convinced that this is just the beginning of what this collaboration will make possible.