DIESEL PLANT – PAINTING OF FREIGHT WAGONS

In 2012, TWEKO completed a unique project for the supply and installation of a painting and drying complex for Diesel Plant LLC in Kryvyi Rih, specializing in the production of freight wagons. The dual painting chamber for wagons provides a full cycle of painting and drying, meeting the highest standards of quality and energy efficiency.

In March 2011, Diesel Plant LLC approached TWEKO with the task of developing equipment for painting railway transport—a painting and drying complex for processing freight wagons. The key requirement was to create two sequentially connected sealed chambers with internal dimensions of 36×5×6 m, capable of simultaneously processing two wagons up to 15 m long each, while maintaining energy efficiency in drying mode.

Project Implementation

Work on the painting chambers for wagons began in March 2011, and by July 2012, installation and commissioning were completed. The complex was installed in the plant’s workshop in Kryvyi Rih on a special foundation base with integrated air ducts for exhaust air and a service pit, allowing painting of the wagons’ undersides.

Over six years of operation (until 2018), the drying chamber for large-scale equipment has performed flawlessly, requiring only scheduled maintenance (replacement of filters, drive belts) and minor repairs to heat exchangers and ventilation units. TWEKO fulfills all contractual obligations, providing prompt service support for the equipment.

Equipment

The painting and drying complex, designed as equipment for painting railway transport, consists of two sequentially connected sealed chambers with total dimensions of 36,000 × 5,000 × 6,000 mm, intended for applying and drying coatings on freight wagons or other large-scale items within these dimensions.

Main components of the booth:

• Walls and ceiling: 80 mm thick sandwich panels with fire-resistant filling (mineral wool), galvanized coating (zinc 275 g/m²), and a polymer layer (0.55 mm), resistant to temperatures up to 180°C and high humidity. This allows the painting chambers to be used even outdoors.
• Suspended plenum ceiling: Made of metal profiles, equipped with fire-resistant ceiling filters with high-quality sealing. The frame design ensures easy filter replacement, crucial for drying chambers.
• Filter cassettes: Vertically positioned in the foundation base under floor grates, capturing paint mist and particles, preventing filter contamination from pit debris.
• Gates and doors: Insulated roller gates measuring 4,000 × 4,500 mm with viewing windows, and three insulated service doors with “anti-panic” locks for safe operation.
• Lighting: Four rows of fluorescent lights (two upper rows at a 45° angle to the ceiling, two side rows), providing at least 1,000 lux for precise quality control of painting. The lights have IP65 protection, ideal for painting chambers for wagons.

Thermo-Ventilation System for Drying Chambers of Large-Scale Equipment

The complex is equipped with four supply and two dual exhaust thermo-ventilation cabinets (TVCs), which provide air purification, heating, and supply, as well as exhaust air removal. Air exchange is at least 200 cycles/hour in painting mode and 50 cycles/hour in drying mode, complying with EU occupational safety standards for railway transport painting equipment.

Each TVC includes:

• A centrifugal fan with an electric motor, with a capacity of up to 40,000 m³/h.
• A heat exchanger made of fire-resistant steel with an NG 350 CIB Unigas gas burner for energy-efficient heating.
• Supply, exhaust, and recirculation dampers with electric actuators.
• A pocket-type pre-filter for air purification before delivery to the plenum.

The temperature is adjustable from 16–24°C in painting mode and 20–70°C in drying mode, ensuring high-quality airflow and drying of wagons in the drying chamber for large-scale equipment.

Control Panel

The automation system includes pressure, temperature, and airflow sensors, counters, and regulators that coordinate the operation of all chamber components. The control panel can be equipped with frequency converters to optimize airflow, enhancing the energy efficiency of painting chambers.

Technological Features

The complex provides a full cycle of pneumatic coating application and drying in the painting chamber for wagons. The chamber is installed on a foundation base with a pit, allowing painting of the wagons’ undersides. The energy-efficient design minimizes costs in drying mode, while sealing and filtration protect against dust, ensuring high-quality coatings for railway transport.

Advantages

1. Unique dual design for simultaneous processing of two wagons in the painting chamber.
2. Energy efficiency due to gas burners and air recirculation.
3. High painting quality thanks to sealing and powerful lighting.
4. Durability and minimal maintenance costs for the drying chamber.

Conclusion

This project marked TWEKO’s first experience in creating a dual painting chamber for wagons of such scale. The implementation for Diesel Plant LLC in 2011–2012 demonstrated our ability to tackle complex technical challenges and deliver durable drying chambers for large-scale equipment. We are proud of this collaboration and ready to offer similar complexes to other enterprises in the railway and industrial sectors.