Powder coating, KTL coating and robot-assisted PU foaming (FIPG) for industry
OSTEKS GmbH
Am Gansberg 2, 09481 Elterlein, GermanyNew on Amplifa
About OSTEKS
OSTEKS GmbH in Elterlein (Erzgebirge, Saxony) is a contract coater specializing in corrosion protection. The company offers powder coating on an overhead-chain conveyor line, KTL coating as an electrochemical dip process, and, since 2021, robot-assisted PU foaming (FIPG) with 1K and 2K systems. The process chain includes pretreatment by degreasing, pickling and zinc phosphating, coating, and stoving; for high corrosion protection with a decorative finish, a multi-layer build-up is offered. In addition, OSTEKS provides delivery and collection service, logistics, upstream and downstream component assembly services, and subsequent assembly operations. Parts made of steel, coil-galvanized steel and aluminum are coated; film thicknesses in the KTL process range from 15 to 60 µm. Customers include the automotive industry and OEMs such as the VW Group and EVOBUS, for whom OSTEKS delivers directly; approvals exist according to manufacturer standards from BMW, Brose, Daimler, Liebherr and VW.
- Site
- Elterlein
- Processes
- Powder coating, KTL coating (electrochemical dip process), 1K PU foaming (FIPG - Foamed In Place Gasket, robot-assisted), 2K PU foaming (two-component polyurethane foam, robot-assisted), Pretreatment: degreasing – pickling – zinc phosphating, Multi-layer build-up (corrosion protection with decorative topcoat), Assembly (subsequent assembly operations), KTL coating
- Materials
- Aluminum, Steel, Steel, coil-galvanized, Polyurethane foam (1K/2K), Powder coating / water-based paint (Axalta, RAL 9005), Powder coating, KTL coating, 1K PU foaming
- Certificates
- ISO 9001:2015, ISO 14001:2015, QIB quality mark (coater qualification DBS 918 340), Saxon Industrial Energy Passport 2025, QIB coater qualification (DBS 918 340), Manufacturer approvals (BMW, Brose, Daimler, Liebherr, VW)
- Industries
- Automotive industry, OEM (VW Group, EVOBUS), Mechanical engineering (Liebherr), Supply industry (Brose), OEM (direct deliveries to VW Group, EVOBUS)
- 01
Incoming goods / delivery and collection service
- 02
Pretreatment (degreasing – pickling – zinc phosphating)
- 03
Powder coating or KTL coating / PU foaming
- 04
Stoving / curing
- 05
Multi-layer build-up (optional)
- 06
Subsequent assembly operations
- 07
Logistics and dispatch
Materials and Processes
Powder coating
Overhead-chain conveyor line with stoving oven (approx. 65 m, up to 230 °C) for parts up to 2,700 × 1,200 × 600 mm and 30 kg.
KTL coating
Electrochemical dip process with film thicknesses of 15–60 µm, curing at 150–200 °C in a continuous oven, up to 500 kg component weight.
1K PU foaming
Robot-assisted, fully automated FIPG system (since 2021) with closed-cell foam for optimal water tightness.
2K PU foaming
Two-component polyurethane foam that cures at room temperature, for sealing industrial components of all geometries.
Steel, coil-galvanized steel, aluminum
Substrates for chemical pretreatment and coating up to corrosivity category C2-H according to QIB.
Multi-layer build-up
Corrosion protection combined with a decorative topcoat for demanding requirements.
Locations
Elterlein
DECoating and foaming facility (production, administration)
- Part weight / size
- Powder: max. 30 kg · KTL: max. 500 kg
- Materials
- Steel, coil-galvanized steel, aluminum, PU foam
- Overhead-chain conveyor powder coating line with stoving oven (approx. 65 m, up to 230 °C)
- KTL system with continuous oven (approx. 15 m, max. 200 °C, work carriers pivotable ± 10°)
- Robot-assisted 1K PU foaming system (FIPG)
- Robot-assisted 2K PU foaming system
Parts
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Powder coatingSurface | – | 2700 mm × 1200 mm × 600 mm | 30 kg | – | – |
| KTL coating (electrochemical dip process)Surface | – | 2600 mm × 900 mm × 2000 mm | 500 kg | – | Steel, Aluminum, Steel, coil-galvanized |
| 1K PU foaming (FIPG - Foamed In Place Gasket, robot-assisted)Plastics | – | – | – | – | – |
| 2K PU foaming (two-component polyurethane foam, robot-assisted)Plastics | – | – | – | – | – |
| Pretreatment: degreasing – pickling – zinc phosphatingSurface | – | – | – | – | Aluminum, Steel, Steel, coil-galvanized |
| Multi-layer build-up (corrosion protection with decorative topcoat)Surface | – | – | – | – | – |
| Assembly (subsequent assembly operations)Assembly | – | – | – | – | – |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Overhead-chain conveyor line (powder coating) with stoving oven (stoving section approx. 65 m, up | – | 1 | 2700 mm x 1200 mm x 600 mm, max. 30 kg | – | Elterlein |
| KTL system with continuous oven (stoving section approx. 15 m, max. 200 °C) | – | 1 | Work carriers 2600 x 900 x 2000 mm, surface 45 m², max. 500 kg | 2018 | Elterlein |
| Robot-assisted 1K PU foaming system (FIPG) | – | 1 | – | 2021 | Elterlein |
| Robot-assisted 2K PU foaming system | – | 1 | – | 2022 | Elterlein |
Additional services
Reference customers
Quality
All work and production systems are monitored by a continuous, process-accompanying quality control. The qualification has been independently audited and confirmed by ISO 9001:2015, ISO 14001:2015 as well as approvals according to customer and manufacturer standards (including BMW GS90011, Daimler DBL, VW TL).
| Evidence | Elterlein |
|---|---|
| ISO 9001:2015 | |
| ISO 14001:2015 | |
| QIB coater qualification (DBS 918 340) | |
| Manufacturer approvals (BMW, Brose, Daimler, Liebherr, VW) |
History
- 2001
Start of powder coating
- 2018
Start of KTL coating with a focus on the automotive industry; initial certification according to ISO 9001:2015
- 2018
Investment in a new powder center and additional guns to increase the coating area and reduce color changeover times
- 2021
Commissioning of the fully automated, robot-assisted 1K PU foaming system (FIPG)
- 2022
Expansion of the foaming technology with a robot-assisted 2K system; initial certification according to ISO 14001:2015
- 2025
Award of the Saxon Industrial Energy Passport on June 18, 2025 in Leipzig for the optimization of the energy-intensive KTL system