A leading enterprise in the field of industrial and medical gases approached TWEKO to modernize its paint preparation area for grinding and coating gas cylinders. As part of the project, a dust extraction booth with air recirculation and a dry-filter spray booth were designed, manufactured, and implemented. The project was delivered on a turnkey basis — from engineering design to commissioning. The result is consistent surface treatment quality, improved operational efficiency, and full compliance with environmental and safety standards.
About the Client
The enterprise operates within the technical gases industry and utilizes equipment for the preparation and filling of gas cylinders of various configurations. The company adheres to strict quality and safety standards typical of modern industrial production.
Its core operations involve supplying gases for industrial processes, which requires consistent surface preparation quality and strict compliance with technological regulations. The need for modernization arose from the requirement to improve the efficiency of grinding and coating processes, ensure stable coating quality, and enhance workplace safety. The enterprise required a solution combining efficient dust extraction, clean air conditions, and ease of operation. Therefore, TWEKO was selected as the contractor for this comprehensive turnkey project.
Project Objectives
- Design and manufacture a dust extraction booth with air recirculation for manual grinding of gas cylinders with a working width of 4 meters.
- Develop a dry-filter spray booth with integrated coating equipment and exhaust air removal through ducting exceeding 20 meters in length.
- Provide a complete project cycle: from concept and engineering to installation, commissioning, and startup, considering on-site conditions.
- Adapt the equipment to the existing infrastructure, including rotating the booths by 90° and integrating with the enterprise’s systems.
- Address technical challenges such as ventilation unit placement, wall openings preparation, and ensuring safe operation.
Solution
A comprehensive equipment system was developed: the ASHF-5 dust extraction booth, built on the principle of an enclosed mini-booth — an isolated working zone made of steel panels that effectively contains dust within the workspace — and the spray booth model KФ.000.00.00-ENERGY from the ASS-Cabin-2 series.
The spray booth is designed for uniform coating application, efficient removal of vapors through dry filtration, and maintaining stable process conditions. Both systems were customized to meet the project requirements, including air recirculation in the ASHF-5 using F7-class filters and exhaust air discharge from the ASS-Cabin-2 via a 560 mm diameter duct.
Adaptation works included modification of air duct routing, installation of a damper, and integration into the existing ventilation system — all implemented without additional cost.
Key Components of the System
| Component | Function Description |
|---|---|
| Dust Extraction Section | |
| ASHF-5 Dust Extraction Booth | Removes dust generated during manual grinding of cylinders on dedicated racks, cleans the air using cartridge filters with pulse-jet regeneration, and recirculates it back into the workshop (F7 class). The two-section enclosed booth design localizes contaminants effectively. |
| C2.1000.10.ANT Filters | Antistatic cartridge filters for fine filtration. Automatic regeneration using compressed air (pressure 6–8 bar, air consumption: 350 L/min). |
| Ventilation Unit | Explosion-proof design, 7.5 kW. Provides airflow up to 13,000 m³/h. Installation height: 2000 mm. |
| Coating Section | |
| ASS-Cabin-2 Dry-Filter Spray Booth | Provides controlled coating of cylinders. Two-stage dry filtration system (cardboard labyrinth filter + PaintStop, ≥95%, EU4) efficiently removes overspray. Exhaust air is discharged through a D560 mm duct to the roof (opening Ø ≈1.1 m). |
| Ceiling Filters | Ensure uniform downward airflow of clean air, maintaining consistent coating quality. |
| Infrastructure and Control | |
| Air Duct System and Damper | Total length exceeds 20 m, suspended from structural columns with 90° bends. Includes a manual damper and integration into the existing system without additional costs. |
| Control Panels | Two control panels (one per unit). Provide control of fans, operating modes, and motor protection systems. |
- ASHF-5 Dust Extraction Booth with Air Recirculation — a custom-designed two-section enclosed booth (model ASF-Cabin-5) developed for industrial cylinder preparation processes. It isolates the working zone, effectively captures dust, and ensures safe and clean manual grinding of gas cylinders. The structure is made of galvanized steel for durability. The system includes an explosion-proof ventilation unit, dust collection container, cartridge filtration system with automatic compressed-air cleaning, lighting, control panel, and complete ducting system. The booth is integrated into the cylinder preparation process, performing surface cleaning from dust, dirt, and corrosion prior to coating. Key advantage — air recirculation: air is cleaned to F7 class and returned to the workshop, reducing energy consumption and eliminating external emissions.
- ASS-Cabin-2 Dry-Filter Spray Booth — a reliable solution for industrial coating areas. Constructed from galvanized steel and equipped with an explosion-proof ventilation system and electric motor, it ensures safe coating application on metal, wood, plastic, and other materials. It efficiently removes overspray, while the two-stage filtration system ensures ≥95% cleaning efficiency (EU4). Cleaned air is discharged to the atmosphere. Key feature — enclosed booth design: adjustable panel length (600–2600 mm) allows precise adaptation to the workspace. Installation requires no preparatory work — only duct connection. The booth is ready for operation within hours.
Technical Specifications
| Parameter | ASHF-5 | ASS-Cabin-2 |
|---|---|---|
| General Parameters | ||
| Airflow Capacity | 13,000 m³/h | 8,000 m³/h (including duct losses up to 40 m) |
| Motor Power | 7.5 kW | 5.5 kW |
| Power Supply | 3-phase, 380 V, 50 Hz | 3-phase, 380 V, 50 Hz |
| Working Area | ||
| Process Type | Manual cylinder grinding | Cylinder coating |
| Working Area Dimensions | 3500 × 2000 × 2400 mm Working width: 4 m |
2000 × 2000 × 2400 mm Gate height: 2800 mm |
| Mini-Booth Configuration | 2 sections, formed galvanized panels | Integrated enclosure (adjustable panels) |
| Filtration and Ventilation | ||
| Filtration Type | Dry, cartridge filtration (C2.1000.10.ANT) | Dry, two-stage: labyrinth filter + PaintStop |
| Filtration Efficiency | F7 (recirculation) | ≥95% (EU4 class) |
| Airflow Mode | Recirculation into workshop | Exhaust to atmosphere |
| Exhaust Duct | — | Ø560 mm spiral duct, roof discharge (opening Ø ≈1.1 m) |
| Filter Cleaning | Compressed air pulse cleaning (6–8 bar) | — |
| Construction and Installation | ||
| Housing | Galvanized steel panels | Galvanized steel panels |
| Ventilation Unit | Explosion-proof | Explosion-proof |
| Lighting | Lighting set + 200 W floodlights ×4 | Sealed LED light fixture |
| Air Duct System | Complete set (>20 m, suspended from columns) | Integrated exhaust system |
| Additional Equipment | Oil separator, pressure regulator (6 bar) | Manual damper, integration into existing system |
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Project Implementation
The project was executed in stages, including site survey, engineering design, equipment manufacturing, installation, and commissioning with full integration into the production process.
Conclusion
The project was delivered on a turnkey basis, from initial survey to commissioning. The system was fully adapted to the enterprise’s operational conditions.
- Efficiency: optimized grinding and coating processes.
- Quality: consistent surface treatment conditions.
- Environmental Performance: reduced emissions through recirculation.
- Reliability: stable and continuous operation.
- Safety: explosion-proof components and antistatic filtration.
TWEKO delivers customized engineering solutions for industrial applications with full process integration.
Looking for a solution for your paint preparation area with dust extraction and air recirculation?
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