In December 2012, TWEKO successfully completed a large-scale project — designing and installing a painting and drying chamber for the Central Depot of the railway station in Tbilisi, Georgia. The pass-through type chamber with unique technical specifications (internal dimensions 32×6.6×6 m) allows for efficient painting of two freight cars or one passenger car simultaneously. The dual-section system ensures independent operation, while a hybrid heating system (electricity/diesel) guarantees reliability under any conditions, even with limited energy resources.
About the Client
The Central Depot of the Tbilisi railway station is a key enterprise in Georgia, specializing in the repair and maintenance of railway cars, including passenger trains. The depot provides technical maintenance, body repairs, and painting of rolling stock to maintain its appearance and durability. High quality standards and the need to operate under limited energy resources require the use of modern equipment, such as painting and drying chambers. TWEKO offers reliable solutions for the railway industry, tailored to the specific needs of clients.
Project Objectives
The project aimed to create a painting and drying chamber for applying and drying coatings on passenger and freight train cars. The main requirements included:
- Designing a pass-through type chamber for simultaneous painting of two freight cars or one passenger car.
- Enabling independent operation of two chamber sections for painting and drying.
- Creating a heating system that operates on electricity or diesel to save energy resources.
- Installing the chamber without requiring a foundation base, with integrated air ducts.
All project requirements were aimed at improving the efficiency of the technological process with minimal energy consumption while creating a safe and ergonomic working environment for personnel.
TWEKO’s Solution: Painting and Drying Chamber for Railcars
TWEKO developed a dual painting and drying chamber of the pass-through type, which included:
1. Chamber Cabin
The chamber cabin has internal dimensions of 32000×6600×6000h mm and protects the painting area from external influences, prevents dust from settling on painted surfaces, and provides thermal insulation. The cabin consists of:
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- Walls and ceiling: sandwich panels with fire-resistant filling, 80 mm thick, with a galvanized double-layer polymer coating (zinc 275 g/m², paint layer 0.55 mm). The panels are resistant to temperatures up to 180°C and high humidity, allowing the chamber to be used outdoors.
- Suspended plenum ceiling: purifies and evenly distributes heated air. The structure consists of metal pipes and angles holding fire-resistant ceiling filters. Specially designed frames with filters ensure high-quality filtration and are easily replaceable.
- Filtration and air ducts: floor grilles with filter cassettes to capture paint mist. Cassettes are placed at the bottom of the side walls, along which exhaust air ducts are located.
- Sealed gates: dimensions 4000×4700 mm, with viewing windows, sectional type, with thermal insulation material and high-quality sealing. Three insulated service doors for personnel.
- Lighting: two upper (angled at 45° to the ceiling) and two side rows of fluorescent lights provide illumination of at least 1000 lux. The lights are IP65-rated (moisture- and dust-proof).
A highly efficient thermoventilation system was designed to ensure a stable microclimate and control air parameters in the chamber.
2. Thermoventilation Group
Consists of four supply and two dual exhaust thermoventilation cabinets (TVCs) that provide air purification, heating, fresh air supply, and removal of used air.
- Temperature ranges: 16–24°C in painting mode, 20–70°C in drying mode.
- Air exchange: at least 200 times/h during painting and 50 times/h during drying, ensuring high-quality drying and safe conditions for operators (compliant with EU standards).
- TVC components:
- Centrifugal fan with an electric motor (up to 40,000 m³/h).
- Vortex heat exchanger with thick-film metal-ceramic heaters — 40% more efficient than traditional heating elements. Designed specifically for painting chambers, more cost-effective than gas heat exchangers.
- Electrically driven dampers for air supply, exhaust, and recirculation, controlled by automation.
- Preliminary pocket filter for air purification before the plenum ceiling.
3. Control Panel
The automation and control system includes:
- Pressure, temperature, and airflow sensors.
- Meters, regulators, and safety systems.
- Frequency converters to adjust motor speeds and airflow in the chamber.
Project Implementation
The request from Tbilisi Central Depot was received in early 2012. TWEKO prepared a commercial proposal, considering energy resource limitations and the requirement for installation without a foundation. After measuring the site, a dual pass-through painting and drying chamber was designed. The manufacturing of components (cabin, thermoventilation cabinets, heating system) was completed in December 2012. Installation and commissioning were carried out on schedule, allowing the chamber to be put into operation as planned.
Results for the Client
- Operational efficiency: The ability to simultaneously paint two freight cars or one passenger car with independent section operation significantly increased process productivity.
- Resource savings: The hybrid heating system (electricity/diesel) reduced energy consumption and ensured stable operation under limited resource conditions.
- High painting quality: Uniform distribution of heated air, effective filtration, and bright lighting (1000 lux) ensured high-quality coating application.
- Structural mobility: Installation without a foundation and with integrated air ducts allowed placement on an existing concrete floor.
- Comfortable working conditions: Powerful ventilation and a modern control system created safe and convenient conditions for operators, compliant with EU labor safety standards.
- Reliability and durability: The chamber’s fire-resistant panels with polymer coating ensure a long service life, even in harsh conditions.
Client Feedback
Head of Tbilisi Central Depot
Conclusion
The successful implementation of the project for Tbilisi Central Depot confirmed TWEKO’s expert approach to engineering solutions in the railway industry. We create equipment that operates reliably, economically, and efficiently for decades.
Painting and Drying Complex: FSC Series
For the needs of the railway, automotive, and other industrial sectors, TWEKO offers the FSC series painting and drying complex. This series combines a painting chamber with a powerful ventilation system and a drying chamber, providing a complete cycle of coating application and drying. The FSC complex optimizes the painting process, ensuring consistent quality through effective air filtration and uniform drying. The solution is ideal for industrial facilities where high productivity and reliability are critical. Learn more about the FSC series painting and drying complex on our website!
