Paint and Coatings Industry Gas Detection Solution: Nexisense Enhances Safety and Environmental Compliance

Nexisense online gas detectors are specifically designed for the paint and coatings industry, supporting real-time monitoring of formaldehyde, benzene, toluene, xylene, VOCs (volatile organic compounds), and combustible gases. Using imported sensor cores, combined with secondary calibration and temperature-humidity compensation, the system ensures high precision and long-term stability. It is suitable for coating production workshops, spraying operation areas, and storage environments, helping enterprises prevent gas leakage risks and improve safety management and environmental compliance.

As a key pillar of the building materials and decoration sector, the paint and coatings industry involves various chemical components during production and application, including film-forming substances, pigments and fillers, solvents, and additives. During manufacturing, storage, and usage, these components may release harmful substances such as formaldehyde, benzene, toluene, xylene, VOCs (volatile organic compounds), and combustible gases. The International Agency for Research on Cancer (IARC) under the World Health Organization has classified formaldehyde and benzene as Group 1 carcinogens, and occupational exposure in paint manufacturing is also considered a potential carcinogenic risk. In recent years, frequent media reports of indoor air pollution after renovation—such as respiratory discomfort or more severe consequences caused by excessive formaldehyde—highlight the necessity of gas detection in this industry.

Installing professional gas detection systems in coating production workshops, spraying areas, or storage facilities enables real-time monitoring of harmful gas concentrations. Once levels exceed thresholds, alarms are triggered immediately, allowing early intervention and accident prevention. As a professional provider of gas sensing technologies, Nexisense offers a series of online gas detectors tailored to the pain points of the paint and coatings industry, delivering high-precision, stable, and reliable monitoring solutions that have been validated in multiple coating enterprises.

Analysis of Common Gas Risks in the Paint and Coatings Industry

Gas risks in paint and coatings production and application mainly originate from raw material volatilization and chemical reactions. Typical hazardous gases include:

• Formaldehyde (HCHO): A colorless, irritating gas, highly soluble in water and commonly used in resin synthesis. Short-term exposure may cause eye and nasal irritation; long-term exposure increases cancer risk.

• Benzene (C6H6): An aromatic compound, sweet-smelling and flammable liquid used as a solvent. Confirmed as a Group 1 carcinogen and may cause hematological damage.

• Toluene (C7H8) and Xylene (C8H10): Derivatives of benzene with high volatility, commonly used as thinners. Exposure may lead to nervous system disorders and liver/kidney damage.

• VOC: A broad term for volatile organic compounds, including the substances above and other chemicals, contributing to photochemical smog and harmful to both environment and health.

• Combustible gases: Such as alkane solvent vapors, which can form explosive mixtures with air and present significant fire hazards.

These gases accumulate more rapidly in enclosed workshops or high-temperature spraying environments. Traditional manual detection methods are inefficient and risky, while fixed online monitoring systems operate 24/7, combined with audible-visual alarms and data transmission for intelligent risk management. Industry data show that enterprises equipped with professional gas detection systems can reduce accident rates by more than 40% while complying with national environmental standards such as GB 30981-2020 (Limit of Harmful Substances in Coatings).

Core Technologies and Advantages of Nexisense Online Gas Detectors

The Nexisense online gas detector series adopts original imported sensors as the core component. Through independent secondary development, calibration, temperature-humidity compensation, signal amplification, and anti-interference optimization, complete wall-mounted or duct-type installation products are formed. For the paint and coatings industry, the system supports simultaneous multi-gas monitoring, fast response time (<30 seconds), and high accuracy (resolution up to 0.01 ppm level).

Product Design Highlights

• High-precision sensor core: Utilizes imported electrochemical, catalytic combustion, or infrared sensors to ensure sensitive detection of formaldehyde, benzene series compounds, VOCs, and combustible gases. Built-in compensation algorithms automatically correct temperature and humidity effects to reduce false alarms.

• Standardized output interfaces: Supports 4-20mA current loop, RS485 Modbus-RTU protocol, relay switch outputs, and other signals for easy integration with PLC, DCS, or cloud platforms. Users can remotely access data for centralized management.

• Convenient installation and maintenance: Wall-mounted design with IP65 protection rating. Corrosion-resistant housing adapts to humid and dusty coating workshop environments. Factory calibrated with long maintenance cycle (sensor lifespan 2–5 years).

Compared with traditional equipment, this series solves issues of unstable signals and susceptibility to interference, helping enterprises save development costs and time. In practical applications, the detector can be linked with ventilation systems or emergency shut-off valves to form a closed-loop safety system.

Environmental Adaptability and Reliability

• Operating temperature range: -20℃ to +50℃;

• Humidity range: 0–95%RH (non-condensing);

• Explosion-proof certification (Ex d IIC T6 Gb), suitable for hazardous locations;

• Low power consumption (<5W) with battery backup to prevent data loss during power outages.

Typical Application Scenarios and Case Sharing

• Production workshop monitoring: Installed in mixing and filling areas to detect VOC and benzene concentrations in real time, automatically activating ventilation when abnormal.

• Spraying operation areas: Duct-type detectors monitor combustible gases and integrate with spray gun control systems to prevent explosion risks.

• Storage and transportation: Wall-mounted devices monitor formaldehyde leakage and upload data to warehouse management systems for remote alerts.

• Laboratories and quality control: Compact online units used for raw material testing to ensure environmental compliance of products.

Multiple coating enterprises have adopted Nexisense solutions. For example, after integrating the detection system into its production line, a large coating manufacturer reduced gas exceedance incidents by 60% and successfully passed environmental audits. In another storage project, the system detected solvent leakage early, preventing a potential fire.

Key Considerations for Implementing Gas Detection Systems

When selecting a solution, enterprises should evaluate on-site gas types, concentration ranges, and installation locations. Nexisense provides full-process services from selection consultation to installation and commissioning, ensuring seamless integration with existing systems. Regular verification (every 6–12 months) is essential to maintain accuracy, using standard gas cylinders for zero and span calibration.

In addition, integrating detection data with enterprise ERP systems via IoT technologies enables predictive maintenance and further optimization of production processes.

Frequently Asked Questions (FAQ)

Q1: Which gases are supported? Can combinations be customized according to coating formulations?
A1: Standard products support formaldehyde (HCHO), benzene (C6H6), toluene (C7H8), xylene (mixed isomers), total VOC, and combustible gases (LEL). Customization for specific solvents or regulatory limits is available, supporting 4–6 gas channels simultaneously.

Q2: How is accuracy and cross-interference in high-solvent environments?
A2: High-selectivity imported sensors (electrochemical or PID) control cross-interference within ±5%. With multi-stage digital filtering and real-time compensation, measurement error is <±3%FS and response time <30 seconds.

Q3: What preparations are required for installation?
A3: Wall-mounted units require 24VDC power and signal wiring. Duct-type units require flange or threaded interfaces. Explosion-proof zones require certified personnel.

Q4: How to integrate with factory automation systems?
A4: Supports 4-20mA, RS485 Modbus-RTU, and relay outputs. Compatible with mainstream PLC, SCADA, and cloud platforms.

Q5: What affects sensor lifespan?
A5: High concentration exposure, extreme temperature/humidity, dust/oil mist, and cross gases. Typical lifespan 2–5 years.

Q6: What certifications are available?
A6: Certified with CMC, Ex d IIC T6 Gb, EMC, compliant with GB 12358-2006 and GB 3836 standards. CE, RoHS, ATEX/IECEx available for export.

Q7: What happens when gas exceeds limits?
A7: Three-level alarms (pre-warning/alarm/high limit) with configurable thresholds, local audible-visual alarm (≥85dB), relay linkage, RS485 transmission, optional SMS/APP push.

Q8: How to obtain samples or quotations?
A8: Contact Nexisense sales or technical support with factory details and monitoring requirements. Response within 24–48 hours.

Conclusion

Gas detection in the paint and coatings industry is not only a safety baseline but also a strategic choice for improving productivity and environmental responsibility. Nexisense online gas detectors provide comprehensive risk control through advanced technology and reliable performance, supporting enterprises in transitioning from passive response to proactive prevention. With increasingly stringent regulations and rising health awareness, early deployment of professional monitoring systems will inject new momentum into sustainable industry development. Nexisense will continue to innovate and collaborate with coating enterprises to build a safer and greener future.