Sanding is not one operation but a sequence: paint removal, feather edging, putty shaping, primer sanding and final preparation. Each stage needs the right abrasive, grit and technique. When the sequence is uncontrolled, the bodyshop pays in repeated passes, wasted abrasives and lost technician hours.
Skilled technician time is today’s real constraint. Extra sanding minutes never appear on the job card, yet over a month of repairs they quietly drain billable capacity. Deep scratches need extra refinement, clogged discs slow every pass, and defects that reach primer or paint mean rework, wasted material and longer turnaround. The right abrasive system stops these hidden losses at the source.
Abrasives should therefore be judged by cost per completed repair, not cost per disc. The solution is to treat preparation as a system: a defined sequence, fewer decisions for the technician and the right product at every stage. That is the principle behind the Kovax Preparation System.
Surface preparation -Kovax Time Saving System
| Step | What happens | Kovax product | Grit |
| 1. Remove | Old paint, rust and failed coatings removed; bare metal and hard putty sanded | Garuda, Maxcut | P80 – P180 |
| 2. Shape | Feather edging and putty shaping to restore the panel contour | Garuda ,Maxfilm | P180 – P320 |
| 3. Refine | Primer sanding to a shallow, uniform scratch | Super Assilex | K600 |
| 4.Control | Defect check, contour sanding and clean dry sanding throughout | Dry Guide Coat, interface pads, 6” sander, dust extraction | All stages |
The Bodyshop-Level Financial Impact
For an individual dealer Bodyshop, a technician-hour recovery of this kind typically shows up in three ways:
- Additional repair capacity — more job cards completed per month from the same headcount.
- Lower rework rates — protecting both margin and customer satisfaction scores.
- Deferred hiring cost — capacity growth without a proportional increase in payroll.
Even a modest recovery in technician-hours, multiplied across a dealer’s monthly job volume, translates into meaningful additional throughput — without added headcount or floor space.
A simulated calculation of Turnaround of an average Bodyshop with Kovax Abrasive Sanding System.
For an individual dealer Bodyshop that repairs 200 cars per month, with an average repair cost of ₹15,000 per car.
| Metric | Value |
| No. of job cards per month | 200 |
| Technicians on floor | 7 Nos |
| Working hours per day | 7.5 Hours |
| Working days per month | 24 Days |
| Total technician-hours per month | 1260 Hours |
| Average repair revenue per job | ₹15,000 |
| Monthly body & paint revenue | ₹30,00,000 |
Expected additional revenue with technician-hour recovery on surface preparation
What the saved time is worth
| Technician hours freed per month | 158 hrs |
| Extra job cards possible per month | +25 |
| Extra revenue per month (25 Job cards × ₹15,000) | +₹3.75 lakh |
| Extra revenue per year (₹3.75 lakh × 12 months) | +₹45 lakh |
Kovax system frees 12.5% of your paint shop’s total technician capacity, without hiring, overtime or extra bays. Surface preparation time falls by about 10% and primer sanding by about 30%, cutting combined surface preparation time by about 17%. That creates room for about 12.5% more job cards and revenue from the same team, along with faster vehicle turnaround. It’s a change in abrasives, not a change in your process.
The future of bodyshop productivity will not come from asking technicians to work harder. It will come from giving them less work to do twice. The repair is won before the paint gun, and it starts with the surface.
Prepare Smarter. Finish Faster.
Up to 12% Quicker Surface Preparation. Up to 50% Quicker Paint Correction and Polishing System.
