The project includes two KASO series abrasive blasting chambers and four IKFS series paint-spray and drying booths, fully integrated into a unified industrial production line for heavy metal structures.
About the Client
The customer is a mechanical engineering enterprise specializing in the design, manufacture, and service maintenance of industrial equipment. The company works with metal products and assemblies where consistent manufacturing quality, long-term coating durability, and repeatable process performance are critically important.
The enterprise delivers comprehensive solutions for industrial clients, covering equipment engineering, fabrication of metal structures, installation, and commissioning of engineering systems for industrial operation.
The company’s primary focus is the development of reliable and efficient process equipment that optimizes production workflows, ensures high quality of finished products, and delivers strong economic efficiency during operation.
Solution
Within the project, TWEKO developed, manufactured, supplied, and commissioned a comprehensive process solution for the preparation and finishing of metal products. The solution combines abrasive blasting, paint application, and subsequent drying under controlled conditions. The equipment layout was designed with consideration for product dimensions, production intensity, and requirements for stable surface preparation quality and coating application consistency.
The solution is built on a modular principle and includes two key process areas: KASO series abrasive blasting chambers and IKFS series paint-spray and drying booths with integrated thermo-ventilation modules. This approach enabled a controlled production cycle for surface preparation and coating application with predictable results at every stage.
- Abrasive Blasting Chambers
For mechanical surface preparation of metal products, the complex includes two industrial-grade abrasive blasting chambers — KASO-12 and KASO-15 — designed for processing large and heavy components. The chambers remove mill scale, corrosion, and process contaminants while forming the required surface roughness profile prior to painting.Both chambers share a unified structural and engineering architecture, including abrasive collection and recycling systems, ventilation, filtration, and automated control. The key difference between the two chambers is the size of the working area, which allows efficient distribution of production flow based on product dimensions and helps optimize equipment utilization.
Structurally, the chambers are manufactured as metal-frame cabins with internal wear-resistant lining, designed for operation under intensive abrasive load. The layout provides convenient service access and safe processing of oversized products within the production workflow.Spent abrasive collection from the working area is implemented via a mechanized scraper floor, which continuously transports material to subsequent processing units without operator intervention.Abrasive delivery to the blasting process is performed by a bucket elevator, after which the media passes through a separator to remove dust, fine fractions, and foreign inclusions. Cleaned abrasive is accumulated in a hopper and returned to the process, ensuring stable blasting parameters and rational media consumption.For dust removal and maintenance of the specified air regime, the chambers are equipped with an industrial-grade filtration and ventilation system that provides controlled air exchange in the blasting zone.
Chamber operation is controlled from a centralized control panel that coordinates key units and enables integration into the overall surface preparation line before painting.
- Paint-Spray and Drying Booths
For coating application and subsequent processing, the complex includes a paint-spray and drying section based on industrial-grade IKFS series booths. The solution is intended for large metal structures and provides stable painting and drying conditions with predictable results at each stage of the process.The IKFS paint-spray and drying booths operate in conjunction with the upstream abrasive blasting area, forming a complete technological cycle for surface preparation and coating application. The booth design and engineering systems are aimed at maintaining a controlled air regime, uniform thermal load, and high-quality final surface finish.
Composition and Configuration of the Paint-Spray and Drying Section
The project included the installation of four paint-spray and drying booths:
- two IKFS series booths, model IKFS-12 — for painting and drying products of standard and medium dimensions;
- one IKFS series booth, model IKFS-15 — for processing longer and more massive products;
- one IKFS Diagonal booth, model IKFS-D-12 — for products with complex geometry or increased dimensions, using a diagonal airflow pattern that обеспечивает efficient air exchange and uniform painting and drying conditions.
This configuration formed a flexible paint-spray and drying section with parallel operation capability, optimal load distribution, and adaptation of the production process to different product sizes.
The booths are manufactured as metal-frame structures with thermally and acoustically insulated panel enclosures, forming a closed working volume with controlled microclimate parameters. This design ensures process stability during painting and effective coating curing during drying.
Airflow organization is implemented via a controlled supply-and-exhaust scheme with multi-stage filtration. This maintains clean air in the painting zone, minimizes dust ingress, and ensures uniform air distribution throughout the booth volume.
Air heating is provided by thermo-ventilation modules with indirect heat exchange, preventing combustion products from contacting the working air. The booths operate in several modes — painting, drying, and cooling — with automated transitions between stages according to a predefined algorithm.
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Rationale for Using Different Booth Types
The IKFS-12 booths are intended for serial painting of standard-sized products and обеспечують high productivity due to the capability of parallel operation. This configuration enables even distribution of production load and execution of painting operations without взаимні downtime between product streams.
The IKFS-15 booth is designed for processing extra-long products or complex metal structures where an expanded working space is required. This booth enables painting of large components without compromising coating uniformity or drying quality.
The IKFS-D-12 Diagonal booth implements a specialized diagonal airflow scheme that differs fundamentally from the classic linear layout of paint-spray and drying booths. Air is supplied and extracted at an angle to the longitudinal axis of the product, which helps create uniform airflow around complex-shaped or oversized structures along their entire length and height.
This airflow scheme is especially effective for painting products with variable cross-sections, large surface areas, or localized zones with increased coating thickness, where stable thermal and airflow balance is critical.
Operating Principle of the Complex
The complex provides a fully closed technological cycle for anti-corrosion treatment of large metal structures — from abrasive blasting to painting and drying under controlled conditions. All process stages are integrated into a single production chain and operate according to coordinated algorithms.
Stage 1. Abrasive Blasting (KASO series chambers)
Surface preparation is performed by abrasive blasting to remove corrosion, mill scale, and process contaminants to the required cleanliness level. The process takes place in the enclosed volume of KASO series chambers with controlled air environment parameters.
Spent abrasive and removed contaminants (rust, mill scale, dust) are collected by a mechanized scraper floor with four conveyors. The mixture is transported by a bucket elevator to a separator, where it is разделена: usable abrasive is cleaned and returned to the hopper for reuse, while dust and waste are removed from the system.
Contaminated air is extracted by an aspiration system with subsequent multi-stage filtration, ensuring stable and safe working conditions for personnel.
Stage 2. Painting and Drying (IKFS series booths)
Painting Mode
Paint application is carried out in the isolated working space of IKFS series paint-spray and drying booths with controlled air environment parameters.
Drying Mode
Coating curing occurs automatically using air recirculation. The cycle includes purge, temperature ramp-up, drying at temperatures up to 80 °C, and controlled cooling.
Technical Specifications of the Complex
Complex Composition:
KASO — 2 chambers; IKFS — 3 booths; IKFS Diagonal — 1 booth*Parameters are provided according to design and operating documentation Parameter Abrasive Blasting Chambers
(KASO-12 / KASO-15)Paint-Spray and Drying Booths
(IKFS-12 / IKFS-15)Paint-Spray and Drying Booth
IKFS Diagonal (IKFS-D-12)General Characteristics Equipment Type Abrasive blasting chamber Paint-spray and drying booth Paint-spray and drying booth Purpose Mechanical surface preparation of metal products Painting and drying of metal products Painting and drying of products with complex geometry Quantity 2 chambers 3 booths 1 booth Dimensional Parameters Internal dimensions (L × W × H) 12,000 × 6,000 × 5,000 mm
15,000 × 6,000 × 5,000 mm12,000 × 6,000 × 5,000 mm
15,000 × 6,000 × 5,000 mm12,000 × 6,000 × 5,000 mm Maximum product dimensions up to 9,000 mm up to 9,000 mm special технологічні scenarios Process Systems Abrasive recovery system Mechanical, closed loop — — Floor type Mechanized scraper floor Filtration floor Filtration floor Heating system Not provided Diesel burners Diesel burner Maximum temperature — up to 80 °C up to 80 °C Ventilation and Filtration Ventilation type Filtration and ventilation Supply and exhaust Supply and exhaust (diagonal airflow scheme) Ventilation capacity 30,000 m³/h 30,000 m³/h × 2 30,000 m³/h × 1 Filtration type Cartridge, multi-stage Dry, multi-stage Dry, multi-stage Operating Parameters Surface preparation grade up to Sa 3 (ISO 8501-1) — — Noise level outside the equipment up to 70 dB up to 70 dB up to 70 dB Power supply 380 V / 50 Hz 380 V / 50 Hz 380 V / 50 Hz
Structurally, the chambers are manufactured as metal-frame cabins with internal wear-resistant lining, designed for operation under intensive abrasive load. The layout provides convenient service access and safe processing of oversized products within the production workflow.Spent abrasive collection from the working area is implemented via a mechanized scraper floor, which continuously transports material to subsequent processing units without operator intervention.Abrasive delivery to the blasting process is performed by a bucket elevator, after which the media passes through a separator to remove dust, fine fractions, and foreign inclusions. Cleaned abrasive is accumulated in a hopper and returned to the process, ensuring stable blasting parameters and rational media consumption.For dust removal and maintenance of the specified air regime, the chambers are equipped with an industrial-grade filtration and ventilation system that provides controlled air exchange in the blasting zone.
Result for the Customer
As a result of the project, a modern industrial complex for mechanical surface preparation and coating application followed by drying under controlled conditions was created, designed for processing large metal products.
The customer received:
- the ability to process large products in chambers of different sizes, adapted to product specifics and production routing;
- a closed-loop process with abrasive recycling, reducing material consumption and minimizing production waste;
- efficient dry air filtration systems in blasting and painting zones, ensuring stable working conditions;
- energy-efficient drying modes using air recirculation and controlled thermal load;
- manufacturer warranty obligations and equipment service life designed for long-term intensive industrial operation.
Conclusions
The comprehensive modernization of the surface preparation and painting area implemented by TWEKO is an example of effective collaboration between a Ukrainian process equipment manufacturer and an industrial enterprise in the mechanical engineering sector.
Thanks to an individual approach — from detailed on-site assessment and technical specification development to equipment manufacturing, installation, and commissioning — the customer received a modern process complex. It includes two KASO series abrasive blasting chambers, three IKFS series paint-spray and drying booths, and one IKFS-D booth, integrated into a single production process.
The equipment is adapted for intensive two-shift operation and processing of large metal structures, ensuring:
- high surface preparation quality and consistent coating application;
- reduced processing time and optimized operating costs;
- compliance with safety, environmental, and occupational health requirements.
All project stages were completed within the agreed timeframe — from equipment delivery to full industrial commissioning. As of the preparation of this case study, the complex operates reliably, without downtime or customer remarks.
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