In November 2024, Alliance Pack LLC, a leading manufacturer of wooden furniture, approached TWEKO to create a spray booth in Zhydachiv, Ukraine. The goal was to modernize the painting department to ensure high-quality application of coatings on chairs and tables. The project’s uniqueness lay in installing the booth on a flat floor without extraction pits, reducing installation costs. After agreeing on technical requirements, TWEKO designed, manufactured, and installed a KF series spray booth with dry two-stage filtration, tailored to the production needs, completing the project in July 2025.
About the Client
Alliance Pack LLC, based in Zhydachiv, Lviv Region, specializes in manufacturing wooden chairs and tables for the Ukrainian and European markets. In 2024, leveraging a grant program, the company decided to upgrade its painting department to improve the quality of coatings, accelerate production processes, and ensure compliance with safety and environmental standards. For this project, Alliance Pack LLC chose TWEKO, trusting our expertise in creating modern spray booths.
Project Objectives
The goal was to modernize the painting department of Alliance Pack LLC by installing a spray booth for applying coatings on wooden products. Requirements:
- Spray booth with internal working zone dimensions of 5000×4100×2600 mm for processing chairs and tables.
- Installation on a flat floor without extraction pits to save costs.
- Dry two-stage filtration with EU3 class cleaning.
- Electric heat exchanger to heat air to +20 °C at ambient temperatures of +5…+10 °C.
- Integration with the client’s utilities and provision of overpressure to prevent dust ingress.
- Project completion by July 2025.
TWEKO’s Solution
TWEKO delivered a comprehensive solution:
- KF.000.00.00-ENERGY Spray Booth (KF-5 Series). The booth, with internal working zone dimensions of 5000×4100×2600 mm and external dimensions of 5120×5290×3010 mm, was installed on a flat floor, eliminating the need for extraction pits and saving costs. Equipped with:
- Electric heat exchanger (24 finned heating elements, total power 72 kW) for heating air to +20 °C at ambient temperatures of +5…+10 °C.
- Two-stage dry filtration system (coarse and fine filters, EU3 class, efficiency up to 89–96.7%) for removing paint aerosols.
- Inlet ventilation unit (VC 14-46 No. 5, AIR 160S6 motor, 5.5 kW, 1000 rpm, capacity 8000 m³/h).
- Exhaust ventilation unit (VC 14-46 No. 4, AIR 132M6 motor, 4 kW, 1000 rpm).
- Lighting (LED lamps, 24 units, 18 W, 6500 K, total power 1 kW, 6500 lumens).
- Control panel with thermostat, hour meter, voltage indicators, and emergency temperature sensors (+90 °C and +115 °C).
- Swing gates (2400×2000 mm) and service doors for convenient access.
- Installation Works. TWEKO performed the dismantling of old equipment, integrated the booth with utilities (380 V/50 Hz power supply, 20–30 kW, with 10 kW for motors and lighting, 10–20 kW for the heat exchanger), routed the exhaust duct through a window, and conducted commissioning.
- Technical Support. Provided supervision installation, staff training, and safety briefings in accordance with GOST 12.2.003-91 and PUE standards.
Project Implementation
Alliance Pack LLC approached TWEKO with a request for an FPH painting station with water filtration and a robot for two workplaces. The need arose due to the modernization of the painting department and the desire to ensure high-quality painting of wooden chairs and tables. The client utilized a grant program to fund the project. After analyzing the client’s needs, TWEKO proposed a KF series spray booth with dry filtration. The project was implemented in several stages:
Stage 1. Site Visit and Technical Specification Approval
TWEKO specialists visited the site in Zhydachiv, conducted measurements, and finalized the technical specifications. Based on the client’s plan (1.7 m clearance from the wall), the booth’s design was adapted, increasing the internal working zone to 5000×4100×2600 mm for convenient painting of chairs and tables.
Stage 2. Design and Drafting
The placement of the thermal-ventilation cabinet (TVC) and exhaust duct through a window was agreed upon, and TWEKO’s team prepared detailed drawings for key components—gates (2400×2000 mm), ventilation units (VC 14-46 No. 5 and No. 4), ACC2.5 cabinet, ceiling, booth, and ducts. The heat exchanger was equipped with 24 finned heating elements (72 kW) for uniform heat distribution, with the TVC designed symmetrically with the heating element outlet on the control panel side.
Stage 3. Preparation for Transport and Shipment
Power requirements were finalized at 20–30 kW (10 kW for motors and 6500 K LED lighting, 10–20 kW for the heat exchanger) to maintain a booth temperature of +20 °C at ambient temperatures of +5…+10 °C. The booth was prepared for shipment under FCA terms, with the client providing transportation, unloading, and necessary equipment, including a covered truck, forklift, and a team of 3–5 people.
Stage 4. Installation, Integration, and Commissioning
Installation was carried out according to the client’s schedule under the supervision of a lead installer. A minor issue with the exhaust duct opening placement was promptly resolved. After integrating the booth with utilities (380 V/50 Hz power supply), overpressure (10–30 Pa) was set up, the two-stage dry filtration (EU3, up to 96.7%) was tested, and all necessary parametric adjustments were made for a safe and efficient launch.
Stage 5. Launch and Acceptance
The booth was successfully launched and commissioned. The client signed an acceptance certificate, confirming compliance with technical documentation, and received a warranty (12 months from launch, up to 15 months from shipment). The client declined a voltage relay, signing a corresponding waiver. TWEKO conducted staff training and safety briefings (GOST 12.2.003-91, PUE).
The client also expressed interest in further modernization—adapting the booth for a conveyor system and creating a drying booth. TWEKO confirmed its readiness to implement such projects in the future.
Results for the Client
- Improved coating quality due to two-stage dry filtration (EU3, efficiency up to 96.7%) and overpressure (10–30 Pa), preventing dust ingress.
- Significant reduction in processing time (approximately 20%) due to optimized painting and heating to +20 °C, increasing the painting department’s productivity.
- Cost savings from installing the KF.000.00.00-ENERGY booth (KF-5 series) on a flat floor without extraction pits, reducing capital expenses.
- Maximum safety with explosion-proof components (AIR 160S6/132M6 motors, sealed LED fixtures), emergency temperature sensors (+90 °C, +115 °C), and compliance with GOST 12.2.003-91 and PUE standards.
- Functional control via a panel with a thermostat, hour meter, voltage indicators, and emergency temperature alerts for ease of operation.
- Flexibility and scalability: the booth can be adapted for a conveyor system or converted into a drying booth without major modifications.
- Reliability ensured by explosion-proof components, high-quality construction, and a 12-month warranty, minimizing maintenance costs.
- Timely project completion and a tailored solution for Alliance Pack LLC’s furniture production, enhancing coating quality and enterprise competitiveness.
Client Feedback
The KF.000.00.00-ENERGY spray booth from TWEKO significantly improved the quality of our chair and table coatings, reducing processing time by 20%. The TWEKO team promptly resolved all technical issues, including the exhaust duct placement, and completed the project on schedule. We are grateful for their professional approach and look forward to further collaboration for modernization!
Vitaliy Kuzma, Director of Alliance Pack LLCConclusion
The project was completed on July 1, 2025, providing Alliance Pack LLC with a modern KF.000.00.00-ENERGY spray booth (KF-5 series). TWEKO adapted the equipment to the client’s needs, performed installation and commissioning, resulting in improved product quality and accelerated production.
The implemented solution ensures efficient and uniform coating application, reduces processing time, enhances workplace safety, and lowers operational costs. The integration of modern filtration, ventilation, and heating systems guarantees stable booth performance, while its flexible design allows for future upgrades to meet additional production needs.
TWEKO’s comprehensive approach demonstrates professionalism in delivering turnkey projects and confirms the reliability and durability of equipment for furniture manufacturers striving for high quality and efficiency.
Modern Solution for Furniture Manufacturers from TWEKO: KF Series Spray Booth
The KF series spray booth from TWEKO is versatile equipment designed for efficient painting and drying of various products. It provides a complete processing cycle: from applying coatings to drying, with customizable temperature and time settings, equipped with intelligent control, two-stage filtration (EU3, efficiency up to 96.7%), explosion-proof lighting, and an energy-efficient heat exchanger.
Key Features:
- Versatility: Suitable for various coatings, including primers, water-based paints, enamels, and varnishes.
- Intelligent Control: Equipped with a programmable logic controller (PLC) that automates painting, purging, and cooling processes, optimizing energy consumption.
- Safety and Compliance: Made from non-combustible materials, equipped with an automatic fire suppression system and explosion-proof fans. An automatic safety interlock stops paint or compressed air supply to spray devices if ventilation fails, ensuring operator safety.
- High Efficiency: High air exchange rate (at least 200 times per hour in painting mode and 100 times per hour in drying mode) ensures uniform coating without runs and rapid drying of painted surfaces.
- Flexible Settings: Temperature adjustment from 16 to 80 °C allows adaptation to specific material and product requirements.
The KF series spray booth from TWEKO is a reliable and efficient solution for businesses engaged in painting various products, ensuring high-quality processing and workplace safety.