Case Study: KASO + IKFS Abrasive Blasting and Painting Complex for Machine Building

The company TWEKO has implemented a project for the development, manufacturing, supply, and commissioning of an abrasive blasting complex and a paint and drying booth for a machine-building enterprise. The aim of the project was to introduce a controlled technological process for the preparation and painting of large-sized products, including surface cleaning, coating application, and drying. As a result, the customer received an integrated system that ensures stable process parameters and seamlessly integrates into the existing production infrastructure.

About the Client

A heavy engineering enterprise with many years of experience in the production of large-scale metal structures and machinery. The technological processes include welding, machining, and surface preparation for the application of paint and coating systems. To ensure consistent coating quality on large-sized products, it became necessary to implement controlled conditions for blasting and painting.

Proposed Solution

TWEKO specialists implemented an integrated technological complex based on the KASO abrasive blasting booth and the IKFS series paint and drying booth. The solution is adapted for processing large-sized products up to 12 meters in length, taking into account the specific requirements of the customer’s production.

The complex provides a sequential cycle of surface preparation, coating application, and drying, with clear separation of “dirty” and “clean” processes. The booths operate autonomously and are integrated into a unified production workflow, ensuring stable air environment parameters at each stage of processing.

Abrasive Blasting and Painting Complex for Large-Sized Products in Heavy Engineering

KASO-7 Abrasive Blasting Booth is equipped with an autonomous dust extraction system with abrasive recovery, including a cyclone separator and a filtration unit. The working area of the booth is 12,000 × 4,800 × 3,580 mm, allowing processing of large-sized products. The capacity of the dust extraction system reaches up to 20,000 m³/h, with an air cleaning efficiency of 96–99%.

The system provides continuous dust removal from the working area and automatic separation of abrasive material with its return to the process cycle. The cyclone separates the heavy fraction, while the filtration unit cleans the air before discharge into the atmosphere. The installed power of the dust extraction unit is up to 30 kW, and the noise level outside the booth does not exceed 70 dB.

The equipment enables simultaneous execution of blasting, dust extraction, and abrasive recovery processes, ensuring process stability and reduced abrasive consumption.

IKFS-14 Paint and Drying Booth is equipped with supply and exhaust ventilation with an air exchange rate of up to 52,000 m³/h, provided by two supply air units with a capacity of 11 kW each and one exhaust unit of 7.5 kW. The working area of the booth is 12,000 × 5,000 × 4,000 mm, allowing processing of large-sized products.

The air treatment system includes multi-stage dry filtration (pre-filters, ceiling filters, and floor filters), ensuring a filtration efficiency of up to 96.7% and uniform airflow distribution within the working area. In painting mode, a positive pressure of 10–30 Pa is maintained to prevent ingress of dust from outside.

Drying is performed using electric heating based on finned tubular heating elements (up to 60 units), with a maximum temperature of up to 80°C. In this mode, air recirculation is implemented with sequential stages: purge, heating, drying, and cooling, ensuring temperature stability and energy efficiency.

The complex is designed with separated technological zones: the abrasive blasting booth operates independently from the paint and drying booth and is equipped with a dedicated dust extraction system with abrasive recovery. A технологical buffer zone (~6.7 m) is provided between the booths, minimizing dust transfer and ensuring separation of “dirty” and “clean” processes.

The system is controlled via a programmable logic controller (PLC) with monitoring of temperature, pressure, drying time, and operating modes.

Project Results

Continuous production processing cycle ensured
Improved surface preparation quality before coating
Abrasive consumption optimized through recirculation
Reduced dust impact on the painting process
Improved working conditions for personnel
Enhanced process controllability through automation

The implemented complex ensures a complete cycle of surface preparation and coating of large-sized products typical for heavy engineering enterprises, including machine beds, frames, housings, and other metal structures. Controlled air parameters and separation of технологical zones ensure consistent coating quality on heavy and geometrically complex products.

The solution is integrated into the existing production infrastructure and can be applied in machine-building, energy, and metallurgical industries where surface preparation and corrosion protection of large-sized products are critical.

Need a solution for surface preparation and coating of large-sized products for your enterprise? Contact TWEKO specialists — we will select the optimal equipment solution according to your dimensions, технологical requirements, and production задач.

Abrasive Blasting and Painting Complex for Large-Sized Products in Heavy Engineering