In 2018, TWEKO implemented a comprehensive project to supply equipment for an abrasive blasting chamber for the Ukrainian industrial enterprise BADOR in the village of Bila, Ternopil Region. The installed abrasive blasting chamber significantly improved the efficiency of surface treatment for semi-trailers and vehicle bodies, optimized production processes, and reduced the company’s costs.

About the Client

Founded in 2000 in the village of Bila, Ternopil Region, BADOR is one of Ukraine’s leading manufacturers of semi-trailers and vehicle bodies. Over the years, the company has earned a reputation as a reliable partner in the repair and modernization of heavy-duty vehicles. BADOR combines a high technical level with a wide range of services, including custom semi-trailer manufacturing, vehicle restoration after accidents, welding, sandblasting, plasma metal cutting, and painting. The company’s commitment to continuous technological improvement and quality enhancement laid the foundation for its collaboration with TWEKO. In 2018, we delivered a customized abrasive blasting chamber project for BADOR.

Project Objectives

The project aimed to create an efficient abrasive blasting chamber for surface treatment within an existing facility measuring 15×6×6 meters. The client required a comprehensive solution that would provide:

• Automated collection and regeneration of abrasive material to reduce costs.
• Effective dust removal to ensure safe working conditions.
• High-performance blast cleaning equipment for processing semi-trailers and vehicle bodies.
• System adaptation to the facility’s constraints and integration with existing production processes.

The project had to be completed within a tight timeframe—from April to May 2018—to minimize production downtime.

TWEKO’s Solution: Abrasive Blasting Chamber

The solution was developed by TWEKO’s engineering and technical department, taking into account all client requirements and production specifics. The company designed and implemented a customized abrasive blasting chamber with an automated abrasive collection and regeneration system and a powerful filtration-ventilation system. The chamber utilized the client’s existing 15×6×6-meter facility, with TWEKO installing a complete set of sandblasting equipment. Key components:

• Scraper Floor. The system consists of six longitudinal modules, each 15 meters long, and one transverse module located at the center of the chamber. The longitudinal modules scrape abrasive and dust from the floor and direct them to the transverse module, which transports the material to a pit beneath the elevator.
• Abrasive Regeneration System. Includes a 7.5-meter-high elevator, a separator, and a 1 m³ storage hopper. The elevator, equipped with a motor-reducer and a belt with buckets, lifts the mixture of abrasive and dust from the pit to a height of 7 meters, where it enters the separator. The separator removes large contaminants and dust, leaving clean abrasive, which is stored in the hopper and fed to abrasive blasting units in a semi-automatic mode.
• Filtration-Ventilation System. A high-performance unit with an airflow of 27,500 m³/h, equipped with 27 filter cartridges with automatic compressed-air cleaning. The system effectively removes dust from the chamber, maintaining a safe working environment.

The scraper floor operates automatically: longitudinal modules transport abrasive and dust to the transverse module, which directs them to the pit. From there, the elevator lifts the mixture to the separator at 7 meters, which filters out contaminants, returning clean abrasive to the 1 m³ hopper. The cleaned abrasive is fed to abrasive blasting units in a semi-automatic mode, ensuring a continuous processing cycle. The filtration-ventilation system ensures environmental compliance and safety, meeting industrial standards.

Project Implementation

TWEKO executed the project on a turnkey basis—from design to commissioning. Work began in April 2018 following a detailed analysis of the facility and the client’s technical requirements. Key stages:

• Design: Development of a layout for blast cleaning equipment tailored to the 15×6×6-meter facility.
• Manufacturing: Production of the scraper floor (6 longitudinal modules of 15 m and 1 transverse), a 7.5-meter elevator, separator, 1 m³ hopper, and ventilation system at TWEKO’s manufacturing facility.
• Installation: Equipment setup, integration with existing systems, and automation configuration for seamless operation.
• Commissioning: Testing of all components, training of BADOR personnel, and commissioning of the blast cleaning chamber.

Installation and commissioning were completed in May 2018, enabling the client to resume production on schedule. The equipment was optimally adapted to BADOR’s needs, ensuring convenient access to semi-trailers and vehicle bodies.

Results for the Client

• Enhanced surface treatment efficiency due to the automated abrasive blasting chamber.
• Up to 80% reduction in abrasive material costs through the regeneration system.
• Improved working conditions thanks to a powerful filtration-ventilation system with a capacity of 27,500 m³/h.
• Stable and uninterrupted equipment operation, ensuring high production efficiency.

Client Feedback

Conclusion

The project for BADOR was successfully completed in May 2018, demonstrating TWEKO’s ability to create reliable and tailored abrasive blasting chambers. The system delivers high performance, resource efficiency, and safety, making it an ideal solution for processing large-scale structures like semi-trailers and vehicle bodies. TWEKO thanks BADOR for their trust and is ready to provide innovative solutions for Ukrainian industrial enterprises.

KASO Abrasive Blasting Chamber from TWEKO

For companies seeking efficient solutions for surface treatment, TWEKO offers the KASO blast cleaning chamber (learn more). This chamber is designed for high-quality surface cleaning from rust, old paint, and other contaminants. Key advantages of KASO:

• Automated Abrasive Collection System: Scraper floor and elevator ensure rapid collection and regeneration of material.
• Powerful Ventilation: Filtration-ventilation unit with automatic filter cleaning guarantees clean air in the chamber.
• Modular Design: The chamber adapts to various facility sizes and production needs.
• Cost-Efficiency: The abrasive regeneration system reduces material costs by up to 80%.

The KASO chamber is ideal for processing metal structures, semi-trailers, vehicle bodies, and other large-scale items. It combines reliability, environmental compliance, and high performance, making it a popular choice among industrial enterprises. Contact TWEKO for a detailed consultation and commercial proposal for your production needs!

The project for the reconstruction and re-equipment of the painting section at Lozova Forging-Mechanical Plant (LKMZ) in Lozova (Kharkiv Oblast) involved a comprehensive modernization of the painting process.

Start of Collaboration

The primary goal of the project for Lozova Forging-Mechanical Plant (LKMZ) was to modernize and optimize the painting process for metal products at the facility. As part of the collaboration with Techservice VEKO and Partner GmbH LLC, initiated following request No. 167 dated September 8, 2016, a new technological line was introduced, processes were automated, and equipment was upgraded.

Project Components

The project included the installation of modern equipment for product preparation, painting, and drying, enhancing production efficiency:

• Abrasive Blasting Chamber (KASO): Used to remove contaminants from product surfaces. The KASO abrasive blasting chamber is a versatile piece of equipment for cleaning products of varying complexity. Its modular design allows adaptation to production needs. An automated process control system ensures high-quality processing and consistent results. The integrated air purification and waste disposal system minimizes environmental impact. For operator safety, the chamber is equipped with an emergency shutdown system and personal protective equipment.
• Conveyor Line: Ensures continuous movement of products through all stages of the painting process.
• Coating Application and Drying Chambers: Designed to provide optimal conditions for painting and drying products. The TWEKO painting and drying complex is an integrated system for applying and drying coatings on various products. It creates an ideal microclimate for achieving high coating quality and maximum production efficiency.
• Ventilation System: Facilitates the removal of harmful substances and maintains the required microclimate.
• Lighting System: Provides adequate illumination for workstations.
• Quality Control System: Enables monitoring of quality at all stages of the process.

Advantages

1. Automation: The introduction of a conveyor line and quality control system increased production efficiency.
2. Quality: The painting and drying complex ensures ideal conditions for coating application.
3. Environmental Friendliness: The waste disposal system in the KASO minimizes environmental impact.
4. Safety: The abrasive blasting chamber is equipped with operator protection systems.

Client Feedback

Lozova Forging-Mechanical Plant (LKMZ) expressed satisfaction with the collaboration with TWEKO, confirming the quality of the work performed:

Conclusion

The modernization project for the painting section at Lozova Forging-Mechanical Plant (LKMZ), completed by September 2016, significantly improved the efficiency and quality of the preparation and painting process for metal products. TWEKO demonstrated its ability to create modern painting and drying chambers for industrial production and efficient abrasive blasting chambers customized to meet the specific needs of our clients. With a flexible approach and experience in delivering complex projects, we are ready to offer solutions that precisely meet your production requirements.

If you are planning to modernize your production and seeking reliable equipment for painting metal products or surface preparation, contact TWEKO. We guarantee a professional approach, innovative solutions, and high quality.

In 2015, we received a request to develop a complex of painting equipment and abrasive blasting equipment for large-scale metal products. The complex was designed to provide a full cycle of preparation for painting — cleaning from scale, rust, and other contaminants, as well as subsequent application and drying of paint coatings. We proposed equipping the painting area with an abrasive blasting chamber featuring systems for automatic shot collection, shot regeneration, and dust removal — a filter-ventilation unit.

About the Client

The Republic of the Union of Myanmar is a country that approached TWEKO with a need for a modern solution for processing large-scale metal products.

Project Objectives

The goal was to provide a complete cycle of preparation and painting of metal products, including cleaning from scale, rust, and other contaminants, as well as applying and drying paint coatings.

TWEKO’s Solution

To ensure an efficient process for applying and drying paint coatings, as well as cleaning products prior to painting, TWEKO’s specialists implemented a comprehensive solution that includes a painting chamber, an abrasive blasting chamber, and self-propelled rail carts with hydraulic lifts. This equipment enables a streamlined production line with optimized movement of products between cleaning, painting, and drying zones.

• Painting and Drying Chamber. The painting chamber has internal dimensions of 12×6×5 m, and the drying chamber measures 10×4×4.3 m, allowing for high-quality paint coating application and efficient drying with minimal energy consumption. The drying chamber is equipped with two thermal-ventilation units with high-efficiency ventilation systems, each with a capacity of up to 25,000 m³. Air heating is provided by electric heat exchangers with a total power consumption of 45–135 kW/h. The painting chamber is equipped with two supply thermal-ventilation units and one double exhaust ventilation unit, providing an airflow of 70,000 m³/h. Air heating is performed by two electric heat exchangers with a total consumption of 60–180 kW/h. Both chambers are equipped with air preparation systems with multi-stage filtration (EU5), which, together with the supply and heating systems, ensure intensive and uniform airflow of clean, heated air at a specified temperature, creating an optimal microclimate for applying and drying paint coatings.

• Abrasive Blasting Chamber. The abrasive blasting chamber has internal dimensions of 12.5×6×5 m. The cabin is made of a steel frame with galvanized steel panels, and the inner surface is lined with a protective rubber sheet to prevent shot ricochet toward the operator and chamber deformation. The shot collection system is implemented as an automatic scraper floor, which collects shot across the entire chamber area and feeds it to the regeneration system. The regeneration system lifts the shot using a bucket elevator to a height of up to 6 meters, cleans it of large particles and dust, and then feeds the cleaned shot into a storage hopper connected to the abrasive blasting apparatus. This creates a closed-loop shot circulation system, significantly improving cleaning efficiency.

• Self-Propelled Rail Carts. During the project implementation, a requirement was added to the technical specifications for moving products between chambers and lifting products within the chambers for painting the underside. To meet this, TWEKO designed and manufactured self-propelled rail carts with integrated hydraulic lifts. The carts have dimensions of 6×2 m and can transport products weighing up to 10 tons between the painting, drying, and abrasive blasting chambers. They are explosion-proof, equipped with low-voltage motor-reducers powered by batteries. Two of the five carts feature a hydraulic lift, allowing the product to be raised up to 2 meters, providing convenient access to the underside for painting.

Implementation Process

The request from the Republic of the Union of Myanmar was received in 2015, reflecting the need for a comprehensive solution for preparing and painting large-scale metal products. TWEKO conducted a detailed analysis of the technical requirements, including specifics of scale and rust cleaning, as well as requirements for coating application and drying. Based on this analysis, a complex of equipment was developed, including an abrasive blasting chamber (12.5×6×5 m) with a shot regeneration system, a painting chamber (12×6×5 m), a drying chamber (10×4×4.3 m), and self-propelled carts (6×2 m) with hydraulic lifts. The implementation accounted for the explosion-proof design of the carts, automated ventilation systems, and electric heat exchangers for air heating. The project was completed in 2015, ensuring the complex was commissioned in accordance with the stated requirements.

Results for the Client

• Complete cycle of preparation and painting of large-scale metal products weighing up to 10 tons.
• Energy savings due to efficient recirculation and heating systems.
• Enhanced safety and productivity through automated systems and explosion-proof equipment.

Client Feedback

Conclusion

The project for the Republic of the Union of Myanmar, completed in 2015, demonstrated TWEKO’s expertise in developing innovative complexes for processing large-scale metal structures tailored to the client’s specific needs.

Need a complex for painting and cleaning? Contact TWEKO — we will find the optimal solution!

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