From raw materials to a polished rig, each step in Pierce’s fire apparatus manufacturing process is critical to achieving a high-quality finished product.

Our Facilities Upgrade Series will offer a behind-the-scenes look at the advanced technologies and strategic investments enhancing our manufacturing processes.

We begin with one of the most critical, and most visible, aspects of apparatus quality: paint.

Learn how new advanced paint booths and curing ovens, buffing robots and an AI-enabled sanding system and layout improvements are helping Pierce deliver premium finishes more efficiently than ever before.

Why Fire Apparatus Paint Matters 

Fire truck painting is a multi-stage process which requires expertise, precision and quality checks at every phase. From surface prep to priming, application, curing and final inspection, each step completed with care results in a high-quality finish for customers.

The New Fire Truck Painting Standard: Upgrades to Pierce’s Paint Facilities

With recent facility enhancements, Pierce is setting a new standard for paint capacity and quality.

By combining expanded facility space with automation and robotic technologies, Pierce’s upgraded paint operations deliver consistency, faster delivery times and improved working conditions for the team members. Here's a closer look at the upgrades:

Expanded Paint Capacity

Pierce has invested in major capacity improvements across its paint operations.

• Additional paint booths were added to increase capacity and reduce lead times.
• Four new metal finishing booths were installed to streamline prep work, minimize bottlenecks and allow teams to maintain a continuous workflow across multiple stages of the paint process.

These enhancements not only increase capacity but also help reduce lead times and better align production timelines across departments.

“By expanding our paint infrastructure, we’re not only improving efficiency, we’re continuing to ensure every fire apparatus that leaves our facility reflects the highest standard of quality our customers expect.” - Cody Jensrud, Production Manager, Pierce Manufacturing

Automation and Robotics in the Painting Process

Automation plays a pivotal role in delivering consistent, high-quality finishes. Pierce’s investments in paint process automation will help support operator efficiency and enhance capacity. Key benefits include:

• Improved consistency in surface preparation, resulting in fewer imperfections and better paint adhesion.
• Less physical strain on team members, allowing operators to focus on quality checks and system monitoring rather than repetitive manual labor.
• Increased efficiency, reducing the time spent on rework and minimizing downstream delays in the paint process.

Automation and robotic technology improve both productivity and ergonomics; key factors in efficient, safe manufacturing.

Paint Base and Clear Coat Robots for Precision Application

In addition to process automation, Pierce has introduced primer application robots which bring a new level of consistency to an essential step in the paint process.

Paint primer robots ensure:

• Even primer coverage, especially across complex contours and surfaces.
• Reduced overspray, minimizing waste and improving environmental control.
• Improved finish durability, with better substrate adhesion for long-lasting protection.

Robotic primer application robots create a safe, ergonomic workspace by limiting team member exposure to chemicals and reducing the need for overhead spraying.

“Robotic paint base and clear coat robots give us the ability to deliver best-in-class coverage while creating a clean, safe environment for our teams.” - Marc Manske, VP of Operations, Pierce Manufacturing 

New Buffing Cells

To take surface finishing even further, Pierce has added dedicated robotic buffing cells; a major advancement in achieving premium finishes with greater efficiency.

These smart robotic cells are engineered for tasks such as sanding, buffing, polishing and coating.

The AI-driven capabilities allow the buffing cells to:

• Adapt to different geometries without constant reprogramming.
• Operate autonomously within the existing production environment.
• Produce a smooth, uniform surface ready for final coatings and inspection.

For Pierce, the investment in robotic buffing cells means high-quality finishes with less manual intervention, reduced variability and improved production flow from start to finish.

See more of the advanced technologies we’ve invested in to help our customers. 

Enhancing Quality Control and Workflow

Facility upgrades at Pierce Manufacturing go beyond advanced equipment and automation. The investments also prioritize smart layout design to support efficient workflow and improved quality at every step. 

Relocated Paint Inspection Light Tunnel

As a critical checkpoint in the painting process, the light tunnel serves as the final inspection area where each painted apparatus is carefully reviewed for surface imperfections, paint inconsistencies or areas requiring touch-ups.

Now relocated to a more central position within the production floor, the light tunnel’s new location significantly improves production flow.

Its placement allows for faster handoffs from paint to inspection and ensures any required adjustments happen without disrupting downstream processes. With this change, Pierce teams can maintain strict quality control while minimizing delays.

Integrated Layout Improvements

Facility layout plays an important role in operational efficiency. Pierce has strategically relocated components within its manufacturing facilities to create a more intuitive flow between fabrication, paint and final assembly stages.

These updates not only reduce physical movement between stations but also lead to:

• Reduced learning curves for new team members, as each phase is more aligned and easier to follow.
• Streamlined collaboration between departments, improving handoffs and reducing the risk of rework.
• More consistent outcomes, thanks to reduced complexity and fewer chances for error.

This thoughtful reconfiguration supports Pierce’s commitment to lean manufacturing and helps ensure the highest quality apparatus are delivered on time.

“Every move we’ve made, from rethinking floor plans to repositioning tools, has been about efficiency and quality for our customers.” - Aaron Lamberg, Director Manufacturing Operations, Pierce Manufacturing 

The Value of Paint Enhancements for Pierce Customers

With recent facility upgrades, Pierce customers can expect:

• Reduced turnaround times for painted components, reducing overall lead time and getting apparatus into service faster.
• Improved finish quality, with better surface preparation and more consistent paint application designed to hold up to the elements and the test of time.
• Greater production capacity to meet demand for both custom-built trucks and stock units, without compromising craftsmanship.
• A continuous commitment to quality; every new booth, robot and layout decision reinforces Pierce’s long-standing focus on durability and customer satisfaction.

With new booths, automation, sanding robots and ergonomic improvements, Pierce is raising the bar for fire apparatus paint standards. The paint facility upgrades streamline processes and support the skilled teams who are committed to achieving a paint finish firefighters can take pride in.

These facility upgrades are just the beginning. Stay tuned for the next installment in our Facilities Upgrade Series, where we’ll highlight more advanced manufacturing investments and how they’re shaping the future of fire truck manufacturing.

Learn more about Pierce’s manufacturing innovations or reach out to your local dealer with questions.