In 2015, we received a request to develop a complex of painting equipment and abrasive blasting equipment for large-scale metal products. The complex was designed to provide a full cycle of preparation for painting — cleaning from scale, rust, and other contaminants, as well as subsequent application and drying of paint coatings. We proposed equipping the painting area with an abrasive blasting chamber featuring systems for automatic shot collection, shot regeneration, and dust removal — a filter-ventilation unit.
About the Client
The Republic of the Union of Myanmar is a country that approached TWEKO with a need for a modern solution for processing large-scale metal products.
Project Objectives
The goal was to provide a complete cycle of preparation and painting of metal products, including cleaning from scale, rust, and other contaminants, as well as applying and drying paint coatings.
TWEKO’s Solution
To ensure an efficient process for applying and drying paint coatings, as well as cleaning products prior to painting, TWEKO’s specialists implemented a comprehensive solution that includes a painting chamber, an abrasive blasting chamber, and self-propelled rail carts with hydraulic lifts. This equipment enables a streamlined production line with optimized movement of products between cleaning, painting, and drying zones.
- Painting and Drying Chamber. The painting chamber has internal dimensions of 12×6×5 m, and the drying chamber measures 10×4×4.3 m, allowing for high-quality paint coating application and efficient drying with minimal energy consumption. The drying chamber is equipped with two thermal-ventilation units with high-efficiency ventilation systems, each with a capacity of up to 25,000 m³. Air heating is provided by electric heat exchangers with a total power consumption of 45–135 kW/h. The painting chamber is equipped with two supply thermal-ventilation units and one double exhaust ventilation unit, providing an airflow of 70,000 m³/h. Air heating is performed by two electric heat exchangers with a total consumption of 60–180 kW/h. Both chambers are equipped with air preparation systems with multi-stage filtration (EU5), which, together with the supply and heating systems, ensure intensive and uniform airflow of clean, heated air at a specified temperature, creating an optimal microclimate for applying and drying paint coatings.
- Abrasive Blasting Chamber. The abrasive blasting chamber has internal dimensions of 12.5×6×5 m. The cabin is made of a steel frame with galvanized steel panels, and the inner surface is lined with a protective rubber sheet to prevent shot ricochet toward the operator and chamber deformation. The shot collection system is implemented as an automatic scraper floor, which collects shot across the entire chamber area and feeds it to the regeneration system. The regeneration system lifts the shot using a bucket elevator to a height of up to 6 meters, cleans it of large particles and dust, and then feeds the cleaned shot into a storage hopper connected to the abrasive blasting apparatus. This creates a closed-loop shot circulation system, significantly improving cleaning efficiency.
- Self-Propelled Rail Carts. During the project implementation, a requirement was added to the technical specifications for moving products between chambers and lifting products within the chambers for painting the underside. To meet this, TWEKO designed and manufactured self-propelled rail carts with integrated hydraulic lifts. The carts have dimensions of 6×2 m and can transport products weighing up to 10 tons between the painting, drying, and abrasive blasting chambers. They are explosion-proof, equipped with low-voltage motor-reducers powered by batteries. Two of the five carts feature a hydraulic lift, allowing the product to be raised up to 2 meters, providing convenient access to the underside for painting.
Implementation Process
The request from the Republic of the Union of Myanmar was received in 2015, reflecting the need for a comprehensive solution for preparing and painting large-scale metal products. TWEKO conducted a detailed analysis of the technical requirements, including specifics of scale and rust cleaning, as well as requirements for coating application and drying. Based on this analysis, a complex of equipment was developed, including an abrasive blasting chamber (12.5×6×5 m) with a shot regeneration system, a painting chamber (12×6×5 m), a drying chamber (10×4×4.3 m), and self-propelled carts (6×2 m) with hydraulic lifts. The implementation accounted for the explosion-proof design of the carts, automated ventilation systems, and electric heat exchangers for air heating. The project was completed in 2015, ensuring the complex was commissioned in accordance with the stated requirements.
Results for the Client
- Complete cycle of preparation and painting of large-scale metal products weighing up to 10 tons.
- Energy savings due to efficient recirculation and heating systems.
- Enhanced safety and productivity through automated systems and explosion-proof equipment.
Client Feedback
Representative of the Republic of the Union of Myanmar
Conclusion
The project for the Republic of the Union of Myanmar, completed in 2015, demonstrated TWEKO’s expertise in developing innovative complexes for processing large-scale metal structures tailored to the client’s specific needs.
