TODD ENGINEEERING

This case study provides a practical example of how automation can complement existing skills and facilities, helping bodyshops improve consistency, efficiency and environmental performance without fundamentally changing how they operate.

Brought to the market by Todd Engineering, a UK spray booth manufacturer working in collaboration with PaintGo, the system is an AI Powered Automated Spray System that combines new technology with existing facilities to deliver consistent, high-quality finishes while reducing waste, energy use, and overall process inefficiencies.

The following questions address the core decision factors a Bodyshop would need to consider when investing in this type of technology; cost and payback, impact on labour and skills, real-world demand, operational benefit and feasibility of investment.

Real-World demand

What challenges in the industry led to the development and adoption of automated spray technology?

The solution was designed to address the variability in finish quality, increased material usage, rework, and inefficient energy consumption due to longer spray times and repeat applications.

Cost, efficiency and workforce impact

Spray booth operations are one of the largest cost and energy drivers in a bodyshop. What measurable savings can be achieved with this system, and what does a typical payback period look like? How does introducing this technology affect the existing skilled workforce?

Operational impact and payback are seen through reduced operating costs, increased output capacity and revenue potential. The technology supports skilled technicians by balancing the challenges presented by the skills gap, reducing variability and rework, and improving working conditions.

Practical value

In practical terms, where does automation deliver the greatest value within the spray process?

• Reduced material waste through precise, controlled application

• Improved first-time quality, significantly reducing rework

• Shorter spray cycles, leading to reduced energy consumption per job

• Lower overall emissions linked to reduced paint usage and booth run time

• Consistent finish quality, independent of operator variability

A further benefit is the reduction in operator exposure to solvents and airbourne contaminants. By minimising the need for prolonged manual spraying within the booth, the system helps reduce day-to-day exposure and supports a safer working environment.

This also has practical implications from a compliance perspective. With less reliance on occupancy, risk assessments and COSHH requirements can be simplified, helping to ease the administrative and operational burden associated with managing exposure risks. This contributes to reduced strain under HSE requirements and supports a more manageable approach to ongoing health and safety monitoring.

Accessibility / realistic investment

Is this a realistic investment for most bodyshops, and how does it integrate with existing facilities without requiring major disruption?

In practical terms the investment is increasingly being viewed as accessible, particularly when weighed against ongoing operational costs. Options such as finance and part exchange can also help manage upfront spend.

The system is designed to integrate with existing spray booth set ups, allowing bodyshops to adopt it without major disruption or a full facility overhaul. Over time, improvements in consistency and efficiency, alongside reduced reliance on manual processes can support increased throughput and better use of materials.

This example demonstrates how AI-led automation can support bodyshops in improving both operational efficiency and environmental performance without disrupting existing ways of working. By complementing skilled technicians, reducing variability and optimising resource use, the technology provides a practical route to lowering energy consumption, minimising waste and supporting a more consistent, sustainable repair process.

"Automation is about supporting skilled technicians, not replacing them. By reducing variability and rework, it helps achieve more consistent, high-quality results while also improving working conditions.

At the same time, it plays an important role in helping bridge the skills gap, giving bodyshops a practical way to improve efficiency and sustainability without needing to completely overhaul existing operations.""