The Client: Titan Fitness Systems
Industry: Commercial Gym Equipment Manufacturing
Location: Industrial Hub, China
The Challenge: Titan Fitness produced over 150 different SKUs, including power racks, benches, and cable machines. Manual painting led to a 12% reject rate due to uneven coating, and traditional robotic options were too complex for their frequent design changes.
The Problem: The "Automation Trap"
Titan Fitness initially looked at traditional industrial robots. However, they realized:
Programming Costs: Hiring a full-time robotics engineer would cost $90,000/year.
Downtime: It took 14 hours to program the spray path for a single new squat rack design.
Wasted Material: Manual painters were using 25% more powder coating than necessary to ensure "full coverage."
The Solution: The CodeFreeSpray Series
Titan Fitness implemented the CodeFreeSpray Lead-Through Robot. Instead of hiring an engineer, they trained their head painter (with 15 years of experience) to "teach" the robot.
"I thought the robot would replace me. Instead, I taught the robot my technique in 10 minutes, and now it does the heavy lifting while I oversee the quality of three lines at once." — Head Painter, Titan Fitness
The Results: By The Numbers
| Metric | Before (Manual/Traditional) | After (CodeFreeSpray) | Improvement |
| Programming Time | 14+ Hours (Traditional) | 6 Minutes | 99% Faster |
| Coating Reject Rate | 12% | < 0.5% | Quality Surge |
| Paint Consumption | $18,000 / month | **$14,400 / month** | 20% Savings |
| Daily Throughput | 45 Units / Shift | 110 Units / Shift | 144% Increase |
The Financial Impact (ROI Analysis)
By eliminating the need for a $90k/year programmer and saving $3,600 per month in paint waste, Titan Fitness reached the Break-Even Point (ROI) in exactly 15.5 months.
Year 2 Projected Savings: $115,000+ in pure operational profit.
Key Takeaways for Your Facility
Complexity is Gone: No-code means you can automate today and see results tomorrow.
Consistency is King: The robot never gets tired, ensuring a premium "showroom finish" on every gym component.
Future-Proof: As Titan Fitness releases new equipment designs, they can program the robot in minutes without outside help.
Ready to write your own success story?
Contact our team atCodeFreeSpray.comfor a customized ROI projection for your factory.