Silhouette Group & Merlin^®

Precise Process Climate for Perfect Eyewear Surfaces: Merlin Technology at Silhouette

Perfect surfaces are a key quality benchmark in eyewear manufacturing. At Silhouette International Schmied AG in Linz, the quality of the coating process depends heavily on precisely controlled environmental conditions. One factor stands out in particular: humidity. It influences electrostatic charges, dust attraction, and the uniformity of surface finishes.

To stabilize these parameters, the Silhouette Group has relied on a high‑pressure humidification system from Merlin Technology since 2019 with impressive results.

Both companies share a central ambition: a commitment to top‑tier quality, sustainability, and reliable production processes. This shared philosophy forms the foundation of a collaboration in which technological precision and stable environmental conditions decisively contribute to a high‑quality end product.

When Humidity Fluctuates, Quality Fluctuates

Before installing the high‑pressure system, Silhouette faced a recurring problem: during extended dry periods, relative humidity in the climate‑controlled painting and coating areas often dropped far below the required 65% at around 23°C.

The previously used pad humidification system was unable to maintain these values reliably and caused fluctuations of up to 15% relative humidity. For sensitive surface processes, this had serious consequences.

All eyewear components whether made of plastic, stainless steel, or titanium are highly sensitive to climatic deviations. Air that is too dry can lead to increased electrostatic charging, more dust inclusions, and visible quality differences in the final product.

Extremely dry outdoor conditions were especially critical: error rates rose significantly on such days, highlighting how strongly process results depended on indoor climate stability.

High‑Pressure Humidification for Maximum Stability

To solve these issues, the Silhouette Group chose the patented ORBIT WING^® high‑pressure system from Merlin Technology. The system was strategically integrated into the climate‑controlled coating zones to ensure exceptionally fine and even humidity distribution.

Unlike the earlier pad system, the high‑pressure solution responds quickly and precisely to deviations, enabling constant humidity control regardless of outdoor conditions. Stable 65% relative humidity significantly reduces electrostatic effects, ensures uniform wetting of surfaces, and delivers reproducible year‑round results.

“With Merlin’s high‑pressure humidification, we can maintain a stable 65% relative humidity in the coating area throughout the year. This has clearly stabilized our processes and reduced the error rate on dry days by around 20%.”
— Thomas Eder, Head of Facility Management, Silhouette Int. Schmied AG

Technology in Use: The Patented ORBIT WING^® System

Silhouette relies on a patented high‑pressure humidification system specifically designed for installation inside ventilation ducts: the ORBIT WING^® System from Merlin Technology. Its unique feature is an aerodynamically shaped, patented wing component that significantly shortens the evaporation distance.

The ultrafine mist is guided into the airflow so effectively that the moisture is absorbed extremely quickly. No aerosols enter the room air an essential factor in sensitive production environments.

In the cleanroom‑like, particle‑sensitive environment used for treating delicate eyewear components, this contributes significantly to process safety and surface quality. The moisture is fully absorbed into the air before reaching the coating zones without droplets, without wetting, and without risk to sensitive surfaces.

Additionally, the system reduces maintenance needs and service costs compared to the previous pad humidification system, further increasing operational reliability.

Reduced Costs, Higher Efficiency, and Enhanced Quality at the Silhouette Group

The stable climate achieved through the collaboration has greatly improved Silhouette’s surface processes. Consistent humidity levels markedly reduce electrostatic charging, resulting in fewer dust particles attaching to sensitive eyewear components.

The result: more uniform coatings and fewer surface defects.
In areas where delicate components are processed and any irregularity becomes visible, the benefits of precise humidity control are especially evident.

Higher process reliability not only reduces material waste but also improves the efficiency of the entire coating line. Stable climate conditions support even layer formation and ensure durable, high‑quality surfaces.

Fact Box: Key Process Data at Silhouette

Parameter	Value	Significance
Relative humidity	65% at approx. 23°C	optimal coating characteristics
Quality improvement	Up to 20%	fewer defects, especially on very dry days
Water quality	Demineralized	hygiene, system protection, trouble-free humidification