PAINTING COMPLEX FOR GENERAL ELECTRIC DIESEL LOCOMOTIVES AT KRYUKOVSKY RAILWAY CAR BUILDING PLANT

In early 2018, PJSC Kremenchuk Carriage Works approached Techservice VEKO and Partner GmbH to modernize the painting complex in CPV-1. The primary goal was to create a modern production environment that would ensure high-quality wagon painting and optimal working conditions.

Start of Collaboration

In February 2018, a framework agreement was signed between PJSC Ukrzaliznytsia and the American corporation General Electric (GE) for the purchase and modernization of 225 locomotives by 2034. General Electric will supply Evolution Series TE33A 5th-generation mainline freight locomotives with asynchronous traction drives—the most advanced platform in GE’s lineup.

In April 2018, representatives of PJSC Kremenchuk Carriage Works (KVSZ) contacted TWEKO with a request for a painting and drying complex for locomotives to be assembled at KVSZ’s facilities under the GE agreement. After a detailed analysis of the technical requirements, we developed a concept for wagon-building equipment, including a degreasing (preparation) chamber, a paint application chamber, and a drying chamber.

All three chambers are integrated into a single complex with shared partitions and hermetic sliding gates, ensuring the product remains within a clean zone throughout processing. The complex is installed on a flat concrete platform. The degreasing and drying chambers are designed for installation without foundation preparation, with exhaust air diverted through side ventilation ducts. The painting chamber features a dual-mode air extraction system (side and underground ducts), improving aerodynamic performance in the work zone. This approach eliminated the need for labor-intensive construction of underground ducts, significantly reducing project timelines.

Painting Complex for Locomotives

The painting and drying complex consists of three zones tailored for locomotive processing:

• Degreasing (Preparation) Chamber: With work zone dimensions of 6,880 × 6,700 × 4,000 mm. The thermo-ventilation group includes one supply-exhaust thermo-ventilation cabinet and a set of bypass air ducts. The cabinet has two centrifugal ventilation units, each with a capacity of up to 30,000 m³/h: one for air supply, the other for exhaust. The chamber is equipped with its own entry gates and gates connecting to the painting chamber.
• Paint Application Chamber: With work zone dimensions of 12,920 × 6,700 × 4,000 mm. The thermo-ventilation group comprises four thermo-ventilation cabinets and a set of bypass air ducts. A total of eight high-performance centrifugal fans, each with a capacity of up to 30,000 m³/h, ensure a constant and uniform airflow at a speed of at least 0.3 m/s. The chamber has its own entry gates and two gates connecting to the degreasing and drying chambers.
• Drying Chamber: With work zone dimensions of 9,880 × 6,700 × 2,700 mm. The thermo-ventilation group includes one supply-exhaust cabinet with a single centrifugal ventilation unit, providing air circulation with partial renewal (10–15%) to prevent explosive environments while minimizing heat loss. The chamber has its own gates and a gate connecting to the painting chamber.

Thermo-Ventilation Group

The complex’s thermo-ventilation system uses six CIB Unigas gas burners (Italy, up to 300 kW capacity) and stainless steel heat exchangers for air heating. All thermo-ventilation cabinets are located outside the facility, 2.5 m from the complex’s cabin. The painting chamber’s ventilation ensures a 0.3 m/s airflow, while partial air renewal (10–15%) in the drying zone guarantees safety and energy efficiency.

Advantages

These solutions enabled:

1. Improved Painting Quality: Precise material dosing and optimal drying modes significantly enhanced the coating quality of locomotives.
2. Increased Productivity: Process automation and optimized operations boosted production volumes.
3. Reduced Costs: The heat exchanger with gas burners consumes half the gas of comparable systems, ensuring high energy efficiency for painting and drying complexes.
4. Better Working Conditions: The new equipment creates safe and comfortable conditions for painting shop personnel.

Results

In December 2018, PJSC Kremenchuk Carriage Works received a new painting and drying complex from Techservice VEKO and Partner GmbH. The equipment fully meets modern wagon-building requirements, ensuring high coating quality and increasing production efficiency. During operation, the complex has performed reliably with no issues regarding quality or functionality.

Conclusion

The 2018 project for PJSC Kremenchuk Carriage Works demonstrated TWEKO’s ability to create advanced wagon painting chambers. The complex combines innovative solutions, such as a dual-mode air extraction system and energy-efficient burners, with minimal construction costs. We are proud of our collaboration with a wagon-building industry leader and are ready to offer similar equipment to other enterprises.