TWEKO designed and implemented a painting complex for railway wagons for SE «Ukrspetsvagon» (Kharkiv region) in 2011–2012. The complex included two painting and drying chambers and two sets of lifting and moving platforms for operators (painters’ lifts). The solution was integrated into the existing infrastructure of the enterprise, considering technological constraints, and ensures efficient, safe, and high-quality wagon painting.
About the Client
SE «Ukrspetsvagon» is a state-owned enterprise in Panyutyne, Kharkiv region, specializing in the production, repair, and maintenance of railway wagons. The company meets the needs of Ukraine’s railway transport, manufacturing and restoring freight and specialized wagons. Its production facilities allow for processing large-scale structures while meeting high quality standards. To achieve high-quality application of coatings, the enterprise required a painting complex adapted to the limited space of the existing facility. TWEKO offers customized solutions for the railway industry — find out how to purchase a painting chamber for your production!
Project Objectives
The goal of the project was to create a painting complex for applying coatings on railway wagons in a constrained space. The main requirements included:
- Design of a painting and drying chamber integrated into an existing facility with three solid walls and a railway track along the facade.
- Effective removal of paint mist using a filtration system with activated carbon.
- Ensuring quick access for operators to wagon surfaces using lifting and moving equipment.
- Optimization of equipment placement for uninterrupted production flow, considering technological priorities and logistical constraints.
- Ensuring operator safety, including an emergency evacuation corridor.
TWEKO’s Solution: Painting Complex for Railway Wagons
TWEKO developed a customized painting complex consisting of two painting and drying chambers and two sets of lifting and moving platforms for operators, adapted to the existing facility. Key components of the solution:
- Painting Zone. Each chamber is equipped with 26 overhead fluorescent lights for high-quality illumination and a two-stage filtration system with activated carbon for effective air purification from paint mist.
- Supply and Exhaust System. Ventilation is provided by eight supply ventilation units and eight exhaust cabinets positioned along the rear wall at a height of 2.4 m. This arrangement ensures clear access to service doors and an emergency evacuation corridor. Heat generators are elevated on platforms with a service area for burner maintenance and operation control. Air is supplied through a vortex heat exchanger with a steam calorimeter, and exhaust is facilitated through an extractor connected to ventilation ducts in the foundation. The extractor can be placed on the chamber’s roof or adjacent structures for flexible integration.
- Lifting and Moving Platforms. Two sets of painters’ lifts, positioned along the chamber’s side walls, allow operators to move freely along the wall, vertically, and toward the wagon surface, significantly reducing manual painting time without interruptions for repositioning. The platforms feature a precise automatic control system, a robust steel structure, and anti-slip coating.
- Construction. The chambers were installed in a facility constrained by three solid walls, with an open facade for the railway wagon transporter. Equipment placement was optimized based on technological priorities to avoid resource congestion and ensure a seamless production flow. The foundation with ventilation duct pits was constructed jointly with the client based on TWEKO’s drawings. The heat generator platforms were manufactured by the client according to TWEKO’s project documentation.
- Control System. The complex is equipped with a control panel with automation that regulates airflow through intake, recirculation, and exhaust dampers, ensuring efficient ventilation and safety.
The set was complemented by ceiling filter frames with mounting elements and filter material for uninterrupted operation.
Implementation Process
The request from SE «Ukrspetsvagon» was received in August 2011. TWEKO conducted an analysis of the facility, identifying technical constraints: three solid walls, a railway track along the facade, and limited ventilation options. After detailed measurements, a project for a railway wagon painting complex was developed. The project accounted for production flow logistics, equipment grouping based on technological priorities, and avoidance of resource congestion.
- Optimal placement of supply and exhaust ventilation systems along the rear wall for efficient air circulation.
- Construction of a foundation with ventilation duct pits for extractor connection, completed by the client based on TWEKO’s drawings.
- Manufacturing of heat generator platforms at a height of 2.4 m with a service area, ensuring access to service doors and an emergency corridor.
- Organization of an emergency corridor for safe operator evacuation in case of an emergency.
TWEKO provided a complete set of project documentation, including drawings for the foundation and heat generator platforms, enabling the client to perform part of the work independently. The manufacturing of components (chambers, ventilation systems, lifting and moving platforms) took place during 2011–2012. Installation and commissioning were completed in 2012, ensuring the complex was operational on schedule.
Results for the Client
- Effective paint mist removal due to a two-stage filtration system with activated carbon.
- Convenient and fast wagon painting using lifting and moving platforms for operators, significantly reducing manual painting time without interruptions for repositioning.
- Optimal equipment placement in a constrained space, considering the railway track and three solid walls.
- Comfortable working conditions due to 26 fluorescent lights and an automated ventilation system.
- Operator safety ensured by an emergency corridor and elevated heat generators with a service platform.
Client Feedback
Production Manager, SE «Ukrspetsvagon»
Conclusion
The project for SE «Ukrspetsvagon», implemented in 2011–2012, demonstrated TWEKO’s expertise in developing painting complexes for railway wagons. The solution, adapted to a constrained space, ensured high coating quality, safety, and production efficiency.
Unified Solutions for the Railway Industry
TWEKO offers comprehensive solutions tailored to the railway industry’s needs — from painting large-scale wagons to ensuring safe working conditions.
