The collaboration between Bicelli and Lesta showcases how automation can revolutionize hydraulic cylinder spraying. By integrating Lesta LEBOT MV A6 robots and the Lesta Production Manager system, Bicelli modernised its painting line, boosting productivity from 300 to 500 units per day with fewer operators.
Automation in hydraulic cylinder spraying is transforming the industrial finishing sector. Increasingly, companies are adopting robotic solutions to boost productivity, improve quality, and reduce costs. A prime example can be seen in the case study of Lesta and Bicelli, a historic Italian manufacturer of hydraulic pumps and cylinders, which implemented Lesta robots with the Lesta Production Manager system to modernise its painting line.
Bicelli: innovation and tradition in hydraulic cylinders
Founded over fifty years ago, Bicelli is a reference point in hydraulic cylinder manufacturing. Its mission is to bring motion to industry through products that combine quality, innovation, and automation. Today, under the leadership of the second generation, Bicelli employs over 60 professionals in a 6,500+ m² production facility, ensuring high quality standards and close customer collaboration.
The challenge: optimising hydraulic cylinder spraying
Before automation, cylinder painting was performed manually. This required four operators to produce roughly 300 units per day. The manual process was labour-intensive and could not ensure the repeatability and quality consistency that a robotic system provides.
The solution: Lesta robots with Lesta production manager
To meet these challenges, Bicelli installed two Lesta LEBOT MV A6 robots, supported by the Lesta Production Manager software.
The Production Manager is a production queue management system that allows operators to select programs and set the number of repetitions, offering maximum flexibility. Programs can be recalled via barcode, RFID tag, or remote management (Web TAG), making the process simple and adaptable to different batch sizes.
Each cylinder model is automatically associated with its specific painting program, eliminating errors and drastically reducing setup times.
Results: increased productivity with fewer resources
Automation delivered immediate, measurable benefits:
- Before: 4 operators for 300 units per day
- After: 3 operators for 500 units per day
By combining Lesta robots with the Production Manager, Bicelli increased productivity by 66%, reduced labour costs, and ensured consistent quality and improved safety for every part.
The Lesta LEBOT MV A6 Robot: versatility and self-learning
The LEBOT MV A6 is a 6-axis articulated robot capable of recording operator movements in real time with its self-learning function. Programming is intuitive: the operator performs the cycle manually, and the robot memorizes and replicates it precisely.
The robot can be installed on the floor, on carousels, with in-line conveyors, or mounted on overhead and floor carts. It is suitable not only for liquid and powder coating, but also for processes such as flaming, drying, and spraying gelcoat, glass fiber, and adhesives.
Available in ATEX and UL hazardous location versions for the North-American market, it offers a flexible solution across multiple industrial sectors.
Lesta Production Manager: Flexible Painting Management
The Lesta Production Manager is a system developed to manage the production queue and the painting programs associated with each part type.
With this system, operators can select which program to run and how many parts to repeat it for, achieving maximum flexibility based on daily production needs.
Programs can be recalled using various methods: by scanning barcodes, via RFID tags applied to pallets, or through the Web TAG mode, which allows for remote management. In this way, each batch is automatically identified, and the robot executes the corresponding cycle without risk of errors.
The Lesta Production Manager also integrates with existing facilities that do not have Lesta robots, supporting both liquid and powder coating, making it a versatile solution for a wide range of industrial environments.
The Bicelli case demonstrates how automation in hydraulic cylinder spraying can deliver tangible and measurable benefits: increased productivity, greater management flexibility, and reduced costs. With Lesta LEBOT MV A6 robots and the Lesta Production Manager system, companies can meet market challenges using reliable and intuitive technologies, transforming painting into a more efficient and competitive process.