TWEKO carried out a full scope of work including design, manufacturing, and integration of a technological surface preparation and paint-drying area for special-purpose equipment for a service enterprise within the TDC group.

About the Client

LLC “TDC Ukrspetstekhnika” is part of the (TDC) group of companies and has been operating since 2010. The company specializes in service maintenance, repair, and supply of spare parts for special-purpose equipment used in agriculture, municipal services, construction, road works, quarrying, and material handling sectors.

The company provides professional repair of power units, transmissions, and hydraulic systems from leading global manufacturers, including WEICHAI, CUMMINS, PERKINS, DEUTZ, CAT, and JCB engines; ZF, CARRARO, and DANA-SPICER transmissions; as well as hydraulic equipment from DANFOSS, BOSCH REXROTH, KAWASAKI, and other brands.

An extensive network of branches in Dnipro, Lviv, Odesa, Kharkiv, and Khmelnytskyi ensures efficient execution of service and production tasks throughout Ukraine.

Project Objectives and Contractor Selection

As part of the development of its service infrastructure, the company identified the need to systematically organize a surface preparation and painting area, taking into account actual repair processes, internal logistics, and integration of equipment into existing production facilities.

To address this task, TWEKO was selected as the engineering contractor capable of delivering a comprehensive solution — from conceptual and layout design to preparation of a complete set of design and technical documentation.

Solution

TWEKO specialists developed a comprehensive engineering solution for organizing a technological area for surface preparation and painting operations within a single production complex.

The equipment configuration, facility layout, and interaction of engineering systems were defined in accordance with the approved technological concept and product movement logistics.

• Abrasive Blasting Chamber

  The first stage of the technological process includes an abrasive blasting chamber of the KASO series, model KASO-12, designed for surface preparation of products prior to subsequent repair and painting operations.

  The chamber is used to remove corrosion, remnants of old coatings, and operational contaminants from metal structures, frames, and components of various sizes.

  

  The chamber is equipped with:

  • A mechanized abrasive collection and regeneration system with a closed-loop cycle, including a scraper floor, bucket elevator, vibratory separator, and storage hopper for reuse of abrasive material.
  • A filtration and ventilation unit with cartridge filter elements and pulse cleaning for removal of dust from the working area air.
  • An organized dust-laden air extraction system from the working zone in accordance with industrial ventilation requirements.
  • Loading access gates for product handling and service doors for personnel, equipped with interlocking safety elements.
  • Wear-resistant internal protective cladding of walls and structural elements, designed for intensive abrasive blasting operation.
  • An industrial lighting system adapted for operation in high-dust environments.
  • An automated control panel providing monitoring of the ventilation unit and abrasive regeneration system operation.
  ТДС-01 – 01-20 КАСО

  ТДС-01 – 01-10 КАСО

• Ventilation Airlock Chamber

  Between the abrasive blasting chamber and the paint-and-drying complex, a ventilation airlock chamber is provided to ensure both technological and air separation between the processing stages.

  The airlock chamber acts as a transitional zone between surface preparation and painting processes, limiting the transfer of dust, residual abrasive, and cleaning by-products to subsequent technological areas.

  Functions of the ventilation airlock chamber:

  • Reduction of dust-laden air migration between chambers and localization of the “dirty” zone within the abrasive blasting area.
  • Equalization and stabilization of airflow prior to transferring parts into the paint-and-drying complex.
  • Formation of a controlled transition zone for product movement without disturbing the operating modes of adjacent chambers.
  • Maintenance of overall process discipline and air cleanliness within the painting area.
  ТДС-01 – 01-31

  ТДС-01 – 06

• Paint-and-Drying Complex

  The final stage of the technological route is a paint-and-drying chamber of the IKFS series, model IKFS-Z-12, divided into separate working zones and intended for the application of paint coatings followed by thermal curing of the products.

  The chamber layout ensures painting and drying operations under controlled air exchange conditions, with the possibility of sequential or parallel processing depending on production requirements.

  

  The paint-and-drying complex is equipped with:

  • A supply-and-exhaust ventilation system with organized airflow, ensuring uniform air distribution in the working zones during painting and efficient removal of paint aerosols.
  • Filtration systems for both supply and exhaust air, designed to reduce aerosol concentration and protect adjacent production areas.
  • Thermo-ventilation units integrated into the chamber structure, providing air heating, circulation, and maintenance of specified drying regimes after painting.
  • An automated control system with an operator control panel, enabling setting and monitoring of painting, drying, purging, and cooling modes, as well as monitoring the status of engineering systems.
  • Technological interlock and monitoring systems preventing chamber operation under unacceptable temperature, pressure, or ventilation and thermal unit conditions.
  • Entry, exit, and inter-zone gates ensuring a pass-through product flow and sealing of working zones during technological operations.
  • An industrial lighting system for the working zones, adapted for painting conditions and long-term operation.
  ТДС-01 – 02-1

  ТДС-01 – 01-1

The proposed solution is formed as a single technological complex with a sequential pass-through processing logic, combining abrasive blasting, a transition zone, and paint-and-drying treatment within a coordinated equipment layout.

The complex is designed with consideration of the facility dimensions, product movement logistics, and engineering utility requirements, ensuring the possibility of further project implementation at the customer’s site without modification of the core technical solutions.

Technical Specifications of the Complex

Operating Principle of the Complex

The technological complex is built according to a pass-through scheme and ensures sequential execution of surface preparation, coating application, and drying operations within a single production workflow.

The process is divided into separate stages with clear isolation of technological zones, which minimizes mutual process interference and ensures repeatable conditions at each stage.

At the first stage, products are fed into the abrasive blasting chamber, where mechanical removal of corrosion, old coatings, and contaminants is performed. The spent abrasive is collected, regenerated, and returned to the working process, while dust-laden air is cleaned by the filtration and ventilation system.

After cleaning, the products are transferred through the ventilation airlock chamber, which forms a transition zone between surface preparation and painting stages, limiting dust transfer and stabilizing airflow.

At the final stage, coating application is performed in the paint-and-drying complex under controlled air exchange conditions, followed by drying of the products at specified temperature modes. After completion of drying, the system switches to purge and cooling modes.

Control of all stages is carried out through an integrated automation system, ensuring synchronized operation of the equipment and compliance with the specified technological sequence.

Result for the Customer

As a result of the project implementation, TDC received a coordinated engineering solution for organizing a technological area for surface preparation and paint-and-drying treatment within a service production environment.

The developed configuration of the complex takes into account real operating conditions, diversity of processed items, and requirements for consistent organization of technological processes.

• A clearly structured technological route with logical sequence of operations and separation of functional zones has been established.
• Risks of negative interaction between surface preparation and painting processes have been reduced through proper zoning of the production area.
• Controlled conditions for coating application and drying have been created, ensuring stable and repeatable quality of the final result.
• A complete set of design and technical documentation has been prepared for subsequent manufacturing, installation, and operation of the equipment.
• An engineering foundation has been laid for further development and scaling of the production area in accordance with the company’s operational needs.

The implemented solution enables the customer to take a systematic approach to organizing refurbishment and painting processes, reducing technological risks during both implementation and operation of the production area.

Conclusion

The project for TDC confirmed TWEKO’s capabilities in developing comprehensive engineering solutions for service and repair production — from the analysis of initial conditions and concept development to the preparation of a complete set of design and technical documentation.

The proposed solution combines a rational equipment layout, a coordinated logic of technological processes, and clearly defined engineering system requirements, creating a reliable foundation for the implementation of the production area and its further development in line with the customer’s operational objectives.

A systematic design approach minimizes risks at the stages of equipment manufacturing, installation, and operation, while ensuring predictable results even before the project enters the implementation phase.

Do you need a custom engineering solution for surface preparation and painting?

The TWEKO team develops abrasive blasting and paint-and-drying solutions with consideration of real operating conditions, production logistics, and the requirements for integrating equipment into existing facilities.

Request a Quote

Poltava Drilling Company LLC, Ukraine’s largest private drilling company, approached TWEKO with the task of modernizing its painting section to enhance the efficiency and safety of processing welded steel structures for drilling equipment. The company’s production facility in Poltava required innovative solutions for applying protective coatings and surface cleaning that comply with international standards and environmental regulations, particularly in harsh conditions (saltwater, gas condensates).
TWEKO delivered a comprehensive solution: a KASO series abrasive blasting chamber and a IKFS Diagonal series painting and drying chamber (KFS). Despite logistical challenges during the martial law period of 2022–2023, the project was successfully completed: processing time was reduced, coating quality improved, and safe working conditions were ensured for operators.

About the Client

Poltava Drilling Company LLC is a recognized leader in Ukraine’s drilling industry with extensive experience, ranking among the top oil and gas operators in Eastern Europe. The company specializes in drilling, well repair, and geological consulting, utilizing advanced technologies such as LWD telemetry and rotary steerable systems for complex conditions. Its products and services are exported to Europe and Asia, and its Poltava production facility is equipped with modern capabilities and engineering teams. To enhance the quality and durability of steel structures prone to corrosion and oil deposits, the company required equipment to prepare surfaces to SA 2.5 (ISO 8501-1) and apply protective coatings with a thickness of 75–125 µm.

Project Objectives

Poltava Drilling Company LLC tasked TWEKO with modernizing the painting section for processing large-scale steel structures of drilling equipment (up to 13,000×3,000×3,000 mm, weighing up to 20,000 kg). The goal was to create a dead-end technological line integrating surface cleaning to SA 2.5 (ISO 8501-1), application of protective coatings with a thickness of 75–125 µm, and drying at temperatures up to 60°C. Per the technical specifications, the complex had to ensure automated abrasive recycling, efficient air filtration, energy efficiency (up to 50 kW for cleaning, 30 kW + 310 kW diesel burner for KFS), and production safety and environmental compliance. The dead-end layout with rail transport optimized the movement of parts within a 40×10×6 m hangar, minimizing downtime and ensuring an efficient workflow.

Solution

TWEKO implemented a comprehensive solution: a KASO-15 abrasive blasting chamber and a IKFS-D painting and drying chamber (model KFS000.00.00-ENERGY “D”) with a working zone of 15,000×5,500×5,000 mm. Both systems were integrated into a unified production cycle via rail carts RTK-20-6 (2 units, 20-ton capacity, speed 0.5–1.5 m/min), enabling seamless part movement between chambers. The abrasive recycling system (KASO), diagonal ventilation (up to 30,000 m³/h in IKFS-D), diesel burner (310 kW), and multi-stage filtration create a closed, energy-efficient cycle compliant with international and environmental standards. Equipment was manufactured at TWEKO’s Kyiv plant, delivered in stages under DDP terms (Incoterms 2010). Installation began in late January 2023 after the client prepared foundations and utilities and was completed in June 2023 with commissioning and operator training (2 operators per shift, working in PPE, 8-hour cycle).

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• KASO-15 Abrasive Blasting Chamber:
  • Cleaning of steel structures from rust, scale, and old coatings to SA 2.5 per ISO 8501-1 (productivity up to 15 m²/h, 6 bar pressure).
  • Automated recycling system for G25–G40 steel shot in a closed cycle (scraper floor, conveyor, separator).
  • Ventilation with 10,000 m³/h capacity, operating temperature +15…25°C.
  • Integration with RTK-20-6 rail cart (20-ton capacity, speed 0.5–1.5 m/min).
  • Safety for two operators: “STOP” buttons, protective barriers, maximum power consumption up to 50 kW.
• IKFS-D Painting and Drying Chamber (Model KFS000.00.00-ENERGY “D”):
  • Application of 1–2 layers of protective coatings (epoxy, epoxy-polyurethane, dry residue ≤65%) via airless spraying, layer thickness 75–125 µm.
  • Automated drying at up to 60°C with an Italian-made 310 kW diesel burner (fuel consumption 8.6–26 kg/h) and diagonal airflow up to 30,000 m³/h.
  • Dry filtration system for exhaust air, gas detector, and automatic fire suppression system with regulatory approval.
  • Operating temperature +15…25°C, maximum power consumption up to 30 kW.
  • Safe operation for two operators in a shared hangar (15,000×5,500×5,000 mm) with 3-leaf gates (3,600×4,000 mm).

Technical Specifications

The complex reduced part processing time, improved coating quality, and ensured safe working conditions, optimizing energy costs even during wartime challenges.

Key Components of KASO Abrasive Blasting and KFS IKFS-D Painting and Drying Chambers

Project Implementation

1. Design: The design of the chambers began with an analysis of the technical specifications, considering dimensions (15,000×5,500×5,000 mm), productivity, and safety, with a commercial proposal (dead-end type). Documentation (foundations, electrical, compressed air, gas) was adapted to a 40,000×10,000×6,000 mm hangar and delivered to the client in January 2023.
2. Manufacturing: Production was completed at TWEKO’s Kyiv plant using durable materials (corrosion-resistant steel, pneumatic cylinders) suited for oil and gas conditions. Martial law in 2022 complicated logistics, but deadlines were met, with manufacturing completed in 2023.
3. Delivery: Equipment was delivered in stages (January–March 2023) under DDP terms (Incoterms 2010) to Poltava in disassembled form for transport convenience, including 2 rail carts and 4 painter carts.
4. Installation: Work began in late January 2023 after the client prepared the hangar (foundation, rails, utilities). Under TWEKO’s supervision, installation continued until late June 2023, concluding with commissioning and testing for hermetic sealing, along with operator training.
5. Training: Personnel underwent training on operation and safety, emphasizing PPE (suit, gloves, helmet) and pre-operation hermetic checks, per instructions.

Operating Principle

The complex operates in a closed cycle, covering surface cleaning and painting per the technical specifications. The KASO chamber uses an abrasive blasting unit with steel shot to remove contaminants to SA 2.5, while IKFS-D applies 1–2 coating layers via airless spraying. Parts (up to 20,000 kg) are moved by rail cart (0.5–1.5 m/min), allowing 2 operators to process complex areas. “STOP” buttons ensure safety. In IKFS-D, coatings are dried at 60°C with a diagonal airflow of 30,000 m³/h, while KASO recycles abrasive. Both systems filter air (10,000 m³/h for KASO, 30,000 m³/h for IKFS-D), maintaining a temperature of +15–25°C and cleanliness, with one 8-hour shift.

Maintenance, Safety, and Warranty Obligations

To ensure long-term, safe, and stable operation, TWEKO developed structured procedures:

• Maintenance: Daily inspections, abrasive recycling (KASO) and ventilation (KFS) checks, weekly air pressure checks (6 bar), monthly filter assessments, quarterly conveyor/burner diagnostics, and semi-annual electrical inspections.
• Safety: Prohibition of opening doors/gates during operation, electrical connections only with power off, mandatory PPE (suit, gloves, helmet). “STOP” buttons, interlocks, and a ban on flammable materials eliminate risks. Malfunctions halt equipment with supervisor notification.
• Warranty: 12 months from commissioning (with manufacturer-supervised installation) or 15 months from delivery per invoice, provided rules are followed. Repairs by TWEKO, parts delivery at the client’s expense.

Results

• Efficiency: KASO increases cleaning productivity to 15 m²/h, and IKFS-D enables coating application and drying at 60°C, both with rail transport for large parts, reducing cycle time.
• Processing Quality: KASO achieves SA 2.5, and IKFS-D ensures 75–125 µm coatings, protecting against corrosion.
• Environmental Compliance: Filtration (10,000 m³/h for KASO, 30,000 m³/h for IKFS-D) and recycling reduce waste, meeting standards.
• Reliability: The design ensures long-term operation with a 12/15-month warranty.
• Safety: “STOP” buttons, gas detector, and PPE protect 2 operators.

Conclusion

TWEKO’s comprehensive production line—KASO abrasive blasting chamber, IKFS Diagonal painting and drying chamber, and rail carts with a traction winch—proved to be an optimal solution for Poltava Drilling Company LLC. It delivered high cleaning and drying productivity, reliable coating protection, operator safety, and environmental compliance through recycling and filtration systems. Even under wartime conditions, the project reduced processing time, lowered energy costs, and enhanced the durability of drilling structures. This underscores TWEKO’s expertise in delivering tailored solutions per technical specifications and contracts—from design to commissioning.

Looking for Solutions for Efficient Surface Preparation and Protection of Steel Structures?

TWEKO’s abrasive blasting and painting/drying chambers offer proven quality, energy efficiency, and customization to meet your production needs.

Request a Commercial Proposal

PrJSC “Dniprovagonmash”, one of the leaders in freight wagon manufacturing in Eastern Europe, approached LLC “Tekhservis VEKO and Partner GmbH” (TWEKO) with a request to develop comprehensive equipment for metal surface treatment. The project aimed to ensure efficient surface preparation (rust, scale, and contaminant removal), high-quality application of paint coatings, process automation, and adherence to high safety and environmental standards. As part of the project, a complex was designed, manufactured, delivered, and commissioned, including a shot blasting chamber of the KASO series and a painting and drying chamber of the IKFS series, customized to the customer’s needs. This integrated system reduced railway wagon processing time, improved surface preparation and coating quality, and ensured safe working conditions despite challenges caused by force majeure circumstances in 2022.

About the Client

PrJSC “Dniprovagonmash” is a leading Ukrainian enterprise with over 90 years of history, ranking among the largest manufacturers of freight rolling stock in Eastern Europe. The plant specializes in the production and repair of various types of freight wagons, including hopper cars, flatcars, grain hoppers, tank cars, and other rolling stock. The company’s products are used both in the domestic market and exported to European and Asian countries.

“Dniprovagonmash” has a modern production base, its own design departments, and implements advanced technologies in mechanical engineering. The enterprise is known for high quality and reliability standards, collaborating with leading railway operators and logistics companies. To ensure stable production levels and compliance with international safety and environmental standards, the customer required modern technological equipment for preparing metal surfaces before applying protective coatings and subsequent painting.

Project Objectives

Develop, manufacture, and supply comprehensive cleaning and painting equipment that meets the following requirements:

• High-efficiency processing of large metal products to remove rust, scale, old coatings, and other contaminants.
• Automation of abrasive material collection, transportation, and regeneration for the shot blasting chamber, and automation of painting and drying with adjustable temperatures and dwell times for the painting and drying chamber.
• Filtration of dusty air and paint mist to create safe working conditions in the work area.
• Compliance with technical standards, including climatic design UHL 4 (GOST 15150-69) and zone class B-IIa per PUE (7th edition).
• Ensuring operator safety and equipment durability.

Solution

TWEKO designed, manufactured, and supplied an integrated complex to PrJSC “Dniprovagonmash”, including a shot blasting chamber of the KASO series (serial number 176/2022) and a painting and drying chamber of the IKFS series (serial number 175/2022). Both systems were adapted to the customer’s needs, considering individual dimensions and components for processing large metal surfaces in industrial conditions.

• Shot Blasting Chamber KASO provides automated abrasive material regeneration, an efficient air filtration system, and safe operation. The design complies with climatic design UHL 4 (GOST 15150-69) and zone class B-IIa per PUE (ed. 7).
• Painting and Drying Chamber IKFS includes an automated ventilation system with air recirculation, “dry” filtration, and a heat exchanger for drying, also meeting the specified standards.

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This complex ensures a full processing cycle: surface cleaning from contaminants and application of protective coatings with subsequent drying.

Key Complex Components

The complex includes components from both chambers, integrated for a continuous cleaning and painting process:

*Components of the abrasive blasting cleaning chamber and painting-drying chamber for PrJSC “Dniprovagonmash”

Component	Purpose
Shot Blasting Chamber	Metal frame clad with 80 mm thick sandwich panels with polyurethane protective coating resistant to abrasive impact. Weight ≈19,000 kg, internal dimensions 25,000 × 7,000 × 7,000 mm. The structure features two service doors (840 × 1975 mm) and roller gates (4500 × 5000 mm) for convenient access to large products. The chamber complies with climatic design UHL 4 (GOST 15150-69) and zone class B-IIa per PUE (ed. 7). Manufactured based on the KASO series shot blasting chamber, which ensures safe and efficient cleaning with shot regeneration in a closed cycle.	Shot Blasting Chamber KASO
Painting and Drying Chamber	Consists of a cabin and ventilation unit. The cabin is a frame structure of profiled pipes, clad with thermally insulated sandwich panels with galvanized coating (zinc 275 mg/m², resistant to 180°C). Weight ≈35,000 kg, internal dimensions 34,220 × 7,000 × 6,050 mm. Equipped with sectional gates (5500 × 4500 mm). The design complies with climatic design UHL 4 (GOST 15150-69) and zone class B-IIa per PUE (ed. 7). Manufactured based on technologies of the IKFS series painting and drying chamber, adapted for efficient application of paint coatings and drying.	Painting Chamber IKFS
Lighting System	Provides uniform and safe lighting in the work area. The shot blasting chamber has 144 LED T8 fixtures (1200 mm, 18 W, 6500 K, IP65), creating illuminance over 700 lx; the painting and drying chamber uses 304 explosion-proof LED fixtures (1200 mm, 18 W, 6500 K, IP65) with ceiling and wall units, ensuring at least 600–800 lx in the painting zone. Complies with safety requirements for zone B-IIa per PUE (ed. 7).	Lighting System
Lifting and Moving Platform	Three-coordinate lift for personnel and tools series 3PtO provides operators with safe access to large products for shot blasting in the cleaning chamber and for applying paint coatings at height in the painting chamber. Load capacity up to 500 kg, equipped with pneumatic system with guide rails and braking system.	Lifting and Moving Platform
Air Duct System	The air transportation system in KASO and KFS includes air ducts of various configurations (DVM.02.00.00.101–107 and DVM.01.00.00.101–204, sheet thickness 0.7–1.0 mm) to ensure efficient airflow in filtration-ventilation units and the ventilation group. Total quantity — 204 units (96 for KASO and 108 for KFS).	Air Duct System
Scraper Conveyor	System for collecting and transporting used abrasive in the KASO cleaning chamber, consists of five longitudinal and one transverse scraper floor modules. Drive provided by two electric motors (1.1 kW, 1500 rpm).	Scraper Conveyor
Bucket Elevator (Bucket Conveyor)	Bucket conveyor KT-5M provides abrasive supply in the cleaning chamber to the separator. Consists of lower, upper, and middle sections with rubber belt (width – 200 mm) and 3 mm steel buckets. Drive provided by two electric motors (1.1 kW, 1440 rpm).	Bucket Elevator
Separator	The separator regenerates abrasive in the KASO chamber, separating dust and debris through a perforated sieve (1 × 1 m, steel with anti-corrosion coating). Equipped with two vibrators (0.18 kW, 3000 rpm).	Separator
Shot Bunker	Conical reservoir made of S235 steel for accumulating cleaned abrasive (steel or cast iron shot, 0.5–1.0 mm), capacity ≈2 m³. Equipped with hermetic construction to prevent abrasive leakage.	Shot Bunker
Filtration-Ventilation Unit	Filtration-ventilation unit (FVU) cleans dusty air with capacity 30,000 m³/h (4 sets, weight ≈2000 kg, dimensions 3000 × 2000 × 2500 mm, each with fan and AIR 160 S4 electric motor, 15 kW, 1455 rpm).	Filtration-Ventilation Unit
Ventilation Group	Ventilation group of the painting and drying chamber includes air supply unit (with supply fan BRV-18, capacity ≈18,000 m³/h), heat exchanger unit (with 198 TOE series heating elements), and exhaust unit (with exhaust fan BRV-18).	Painting and Drying Chamber Ventilation Group
Filters	“Dry” filtration system of the painting and drying chamber with pre-cleaning filter (efficiency ≈89%, replacement every 500 hours), ceiling filter (acrylic, efficiency ≈96.7%, replacement every 500 hours), and floor filter (fiberglass, efficiency ≈93%, replacement every 80–100 hours).	Painting and Drying Chamber Filters
Heating and Drying System (including heat exchanger)	Provides KFS chamber heating with 198 tubular electric heaters (TEN) in TOE series heat exchanger (power 200 kW, made of AISI 304 stainless steel).	Heating and Drying System
Abrasive Blasting Chamber Control Panel	Provides centralized control of all abrasive blasting chamber systems: has switches for main equipment power supply (380 V / 50 Hz) and chamber lighting (220 V / 50 Hz), “START” and “STOP” buttons, indicators for filtration-ventilation units operation, scraper floor drives, bucket conveyor, signal lamps for motor overload and bunker overflow. Equipped with operating hours counter and pressure sensors in compressed air main line (0–10 bar).	Abrasive Blasting Chamber Control Panel
Painting and Drying Chamber Control Panel	Provides full control of painting and drying chamber modes. Equipped with two-channel temperature controller, drying dwell timer, potentiometer for excess pressure regulation, actual pressure indicator, light indicators for supply and exhaust fans, electric heaters, emergency conditions, gas detector, “START” / “STOP” buttons, mode switches, and emergency stop.	Painting and Drying Chamber Control Panel
Operating Hours Counter	Designed to track total operating time of chambers. The painting chamber uses DHM-48 type motor-hour meter with RESET function for resetting readings (e.g., after filter replacement). The abrasive blasting chamber uses motor-hour meter for component wear monitoring without reset function.	Operating Hours Counter
Gas Detector	Available only for the painting chamber. Uses DOZOR-S type gas analyzer to monitor gas concentrations (5–50% LEL), blocks equipment when thresholds are exceeded to ensure safety in painting mode.	Gas Detector
Temperature Setting	Available only for the painting chamber. Implemented through two-channel temperature controller (LU-1 for painting, LU-2 for drying) with set range up to 90 °C, displays actual and set temperature to maintain optimal drying conditions.	Temperature Setting
Drying Cycle Dwell Time Setting	Available only for the painting chamber. Uses EDR-48 type timer with range 00:00–99:99 (min:sec), starts countdown after reaching set temperature to control drying process.	Drying Cycle Dwell Time Setting
Excess Pressure Setting	Available only for the painting chamber. Regulated by potentiometer through frequency converter, maintains working pressure 30–50 Pa, equipped with draft-pressure gauge for chamber pressure monitoring.	Excess Pressure Setting

Principle of Operation

The complex operates on an integrated cleaning and painting cycle for metal surfaces in industrial conditions, ensuring continuous preparation and processing of products while complying with safety and environmental standards.

• Shot Blasting Chamber KASO: The operator uses an abrasive blasting gun to process metal parts with steel or cast iron shot, effectively removing rust, scale, old coating residues, oil, and other contaminants from surfaces within the chamber’s internal space. The process occurs under climatic design UHL 4 (GOST 15150-69) conditions, ensuring zone class B-IIa (PUE, 7th edition). Four 3PtO series lifting-moving platforms, equipped with pneumatic system with guide rails, brakes, and height adjustment, provide safe access to all product areas, allowing movement in three directions. Used abrasive is collected by scraper conveyor, which transports it to bucket elevator. The elevator lifts abrasive to separator, where dust and debris are sieved through perforated sieve with vibrators, after which cleaned abrasive accumulates in conical bunker with capacity up to 2 m³ for reuse. Dusty air is exhausted through four filtration-ventilation units (FVU) with capacity 30,000 m³/h each, equipped with cartridge filters regenerated by pulse blowing with compressed air (pressure 6 bar, class not lower than 9 per GOST 17433-80, with drying to dew point -30 °C for external installation). The process is controlled by central control panel, equipped with power switches, “START” and “STOP” buttons, FVU operation indicators, conveyor drives, motor overload and bunker overflow signal lamps, as well as motor-hour meter and compressed air main line pressure sensors, ensuring continuous monitoring and quick response to malfunctions.
  
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• Painting and Drying Chamber KFS: After cleaning, products are moved to the painting chamber, where paint coatings are applied by pneumatic manual spraying under climatic design UHL 4 (GOST 15150-69) and zone class B-IIa (PUE, 7th edition) conditions. Air enters through intake valve, passes pre-cleaning filter (efficiency ≈89%), TOE series tubular heater heat exchanger, and ceiling filter (acrylic, efficiency ≈96.7%, resistant to temperatures up to 100–120 °C), ensuring clean environment with maintained excess pressure 30–50 Pa. Ventilation is provided by six supply and six exhaust ventilation units (capacity ≈18,000 m³/h each), equipped with motors (7.5 kW, 1000 rpm) for supply and (5.5 kW, 1000 rpm) for exhaust, meeting explosion-proof zone class 2/22 (PUE) and DSTU B A.3.2-12:2009 requirements. In drying mode, the chamber operates in three-stage cycle: blowing to remove paint residues, drying with recirculation through heat exchanger (maximum temperature ≈90 °C, provided by 198 TENs), and cooling, with automatic LED fixtures (18 W, 6500 K) shutdown to protect from overheating. Additional exhaust air filtration is provided by floor filter (labyrinth/cardboard/fiberglass, efficiency ≈93%) and outlet filter (TPS-50 fiberglass, efficiency ≈75%). For convenient access to large products during coating application, 3PtO series lifting-moving platforms are used. The process is controlled by control panel with two-channel temperature controller (LU-1 for painting, LU-2 for drying), dwell timer (range 0–99 minutes), potentiometer for fan frequency converter regulation, pressure indicator, node operation light indicators, ventilation and heater blocking system when gas detector (range 5–50% LEL) is triggered, and “START”/”STOP” buttons with emergency stop, ensuring safety and operation accuracy.

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This integrated approach minimizes material losses, maintains high processing quality, and ensures safe working conditions, complying with fire safety and environmental standards.

Technical Specifications of Abrasive Blasting and Painting-Drying Chambers

Maintenance, Safety Procedures, and Warranty Obligations

LLC “Tekhservis VEKO and Partner GmbH” developed procedures for uninterrupted complex operation.

1. Maintenance: For KASO — daily inspection, separator and FVU emptying, weekly valve check, monthly filter check, quarterly conveyor and fan check, semi-annual electrical circuit check. For IKFS — daily filter inspection, weekly fan check, monthly filter replacement, quarterly heat exchanger check, semi-annual contact check.
2. Safety Procedures: Prohibited to open doors/gates during operation, use solvents (KASO) or work without grounding (IKFS). Mandatory PPE. KASO equipped with limit switches, IKFS — gas detector.
3. Warranty: 12 months from commissioning (if installation under manufacturer supervision) or 15 months from delivery date. Does not cover instruction violations. Repair — by LLC “Tekhservis VEKO” representatives, transportation — at manufacturer’s expense.

Results

• Efficiency: The complex increased productivity through automated cleaning (KASO) and painting/drying (IKFS), reducing processing time.
• Processing Quality: KASO ensures thorough cleaning, IKFS — uniform coating application and drying, improving corrosion protection.
• Environmental Safety: Dust filtration (KASO) and paint mist filtration (IKFS) comply with environmental standards.
• Reliability: Service life 10 years with overhaul resource 5 years for both chambers.
• Safety: Safety automation (KASO) and gas detector (IKFS) minimize risks.

KASO and IKFS Complex Chambers for Railway Transport from TWEKO

The abrasive cleaning, painting, and drying complex is an integrated solution for cleaning metal surfaces from rust and applying protective paint coatings. KASO uses abrasive blasting technology with abrasive regeneration, while IKFS provides pneumatic painting and drying with air recirculation. Both systems feature efficient filtration, lighting (over 700 lux), and automated control. Developed individually according to technical specifications. The complex from LLC “Tekhservis VEKO and Partner GmbH” became a key solution for PrJSC “Dniprovagonmash”, ensuring high productivity, cleaning and painting quality, safety, and environmental compliance. The equipment meets modern standards and supports freight wagon production, reducing time and costs.

Need a comprehensive cleaning and painting solution? Choose KASO and IKFS from TWEKO!

Request Commercial Proposal

In November 2021, TWEKO completed a project for LLC “Krok Wood” (Svalyava) to implement a spray booth — model KF 000.00.00-ENERGIYA of the FPH series — equipped with water curtain filtration. The system created a controlled environment for applying paint and coating materials in a woodworking facility while meeting safety, temperature stability and maintenance requirements.

About the Client

LLC “Krok Wood” is a Ukrainian manufacturing company established in 2010, specializing in woodworking and furniture production. Located in the Zakarpattia region, the company serves both domestic and international markets.

Its production cycle covers wood processing through to finished products. To maintain consistent coating quality and comply with occupational health and safety standards, the company required a properly controlled painting area.

Project Objectives

• Commission the FPH-2.5 water-wash spray booth in full accordance with operating documentation.
• Establish stable supply and exhaust ventilation with multi-stage air filtration.
• Ensure precise temperature control within the working zone.
• Develop and implement a routine maintenance schedule and operator procedures.

Solution

The project covered the complete engineering cycle: design, fabrication, delivery, installation and commissioning of the KF 000.00.00-ENERGIYA spray booth (FPH-2.5 series), manufactured by LLC “Techservice VEKO i partner GmbH”.

All structural elements, unit layout and control logic were tailored to the production requirements of LLC “Krok Wood” and the specific needs of a woodworking painting department.

The booth operates on a vertical downdraft supply-exhaust principle with multi-stage supply air filtration and exhaust air cleaning via a water curtain followed by a final-stage filter.

Scope of supply and works included:

• Installation of the booth frame and enclosure in a dedicated production room;
• Integration of supply and exhaust ventilation system and hot-water air heating module;
• Connection of the heat-carrier circulation loop and control/shut-off valves;
• Configuration of automation system, temperature control and warm-up sequence;
• Full commissioning, performance testing and handover.

Commissioning was completed in full compliance with fire, industrial and electrical safety regulations applicable to Class B-IIa premises and handling of flammable coating materials.

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Key System Components

• Ceiling plenum with final filters — ensures uniform distribution of conditioned supply air and creates a stable vertical downdraft across the working area.
• Supply air handling unit — delivers filtered and heated air to the plenum; driven by a 5.5 kW motor.
• Exhaust fan unit — removes contaminated air from the booth and discharges it outside; driven by a 4 kW motor.
• Water-to-air heat exchanger — heats incoming air using hot water; complete with circulation pump and control/shut-off valves.
• Water curtain — captures the majority of paint overspray, reducing aerosol concentration in the exhaust stream.
• Automatic control system — monitors working zone temperature, manages heat exchanger warm-up and provides system status indication.

Technical Specifications — KF 000.00.00-ENERGIYA (FPH-2.5)

Operating Principle

The booth operates on a vertical downdraft principle. Ambient air passes through a pre-filter, then through the water-to-air heat exchanger where it is heated to the required set point.

The conditioned air is distributed through the ceiling plenum and final filters, forming a uniform downward airflow across the working zone.

During spraying, overspray particles are entrained by the downdraft and directed toward the rear exhaust section. Exhaust air passes through the water curtain where the majority of paint particles are captured, followed by final filtration before discharge outside the building.

This configuration ensures stable air exchange, consistent temperature control and reduced aerosol concentration within the working area.

Maintenance & Safety

Filter replacement intervals are based on operating hours. Electrical connections are inspected every 100 operating hours, and seals are checked for integrity. All work is performed using appropriate personal protective equipment.

The booth complies with fire safety regulations for Class B-IIa premises. High-temperature monitoring and ventilation fault indication are provided.

Results

• Controlled environment for consistent coating application achieved.
• Stable and repeatable temperature conditions in the spray zone.
• Multi-stage air filtration implemented.
• Improved safety and workflow organization.
• Clear maintenance schedule and operator procedures established.

Summary

The project for LLC “Krok Wood” demonstrated the effectiveness of the FPH-2.5 water-wash spray booth in woodworking production. The solution successfully integrated a controlled painting process into the company’s manufacturing flow.

Request Consultation on Painting Area Equipment

Painting trucks, cars and truck cabins

At the beginning of the summer of 2021, we received a request for the development and design of a spray booth, which was needed for military unit № A3358. Purpose: to accelerate the release of finished products and improve the quality of painted car parts, paint trucks, vans and their parts. The technical specialists of the military unit were offered our standard AKFS-S chamber with electric heating, air supply from the ceiling and exhaust from the floor.

What tasks the spray booth was supposed to solve:

• truck painting \ truck body painting
• car painting \ car cabins painting
• painting of cabins of trucks and minibuses
• painting of body parts

Car body painting

The technology of painting a car is a difficult and time-consuming process in which a good result can be achieved only if the painting technology is followed and with certain skills. The main principle of obtaining high-quality painting of cars and body parts is a phased preparation and a clear sequence of actions of the painter who conducts the painting work. Thanks to a huge selection of painting materials and the right tools, you can get the desired result, and the impact of the environment on the damaged areas of the car.

A damaged paintwork not only spoils the appearance of the car, but also leads to metal corrosion, which entails a lot of troubles, complicates the painting of the damaged part. In the case when painting is carried out without eliminating problems on the body, after a while the paint begins to flake off and “mushrooms” are formed. Intervention of welding is required, possibly a partial repair of the insert of a new element, or a complete replacement of a part. In order to thoroughly prepare the metal for painting, it is necessary to use specialized equipment, to clean the metal from the coating residues using shot blasting.

Once again, our company was noted for the speed and quality of manufacturing a chamber for painting and drying (CFS) cabins of trucks, minibuses and their body elements. FSC with working area dimensions 8.6 x4, 5×3, 0 is already standardized equipment for our design bureau, so the development took a short period of time.

Installation of equipment for painting cars and cabins

Installation of equipment with a supply and exhaust ventilation duct took a record 4 working days, taking into account the change of the supply ventilation duct line and the manufacture of new ducts. Commissioning and personnel training took only 1 working day, during which the customer’s personnel fully learned how to use the equipment.
An important role in the installation work was played by the assistance provided by the customer with personnel and mechanisms, for which we express our deep gratitude to military unit No. A3358!
At the moment, the equipment works according to the factory settings and in normal mode, the customer is satisfied with the operation of the equipment, as evidenced by the letter sent to us on October 21, 2021.

MAINTENANCE OF THE PAINT STATION LLC “VKP PARITET-K”

We got acquainted with PKP PARITET-K LLC back in 2015. The company is engaged in the production of locks, safes, hinges, hinges and other metal products. The development of our acquaintance then became the order and installation of a painting and drying station in two thousand and sixteen, and last month, 2021, company employees contacted us about the maintenance of this camera.

MAINTENANCE OF THE PAINT STATION

The specialists of the service department of LLC Techservice VEKO & Partner GmbH carried out repair work on the painting booth with an electric heat exchanger at the customer PARITET-K. Over the long 5 years of intensive work, some of the functional elements of the painting station have worn out a little and require repair, about which a defect report and a plan for performing maintenance work were drawn up.

After finalization, the following works were carried out for the approval of this act:

fresh air filters were replaced
exhaust ventilation filters replaced
revision and adjustment of the control panel made
part of the electric heaters was replaced
the operation of the gate devices and thermostats was restored.

SUMMARY

Our specialists noted that for such a long period, which is more than five years of operation, the equipment is in a satisfactory technical condition. The company carried out a technical inspection of the equipment in a timely manner according to the recommendations. It can be seen that the camera and additional equipment were monitored, for which we are grateful to the employees of VKP PARITET-K LLC.

At present, the equipment is operating normally, fulfills its function and gives out the technical indicators stated in the equipment passport!

Painting area is

A painting area is a painting complex consisting of several chambers, one of which is painting the other is drying, as well as a preparation post for painting.

The site consists of three production departments, functionally closely interconnected, these are:

• Department of preparatory work;
• Painting department;
• Drying department;

“LLC” AGROKUB

Thanks to the efficient work of the sales department of our company, we got acquainted with the company AGROKUB LLC. During further communication with the management and the technical department of this company, it was found out what equipment for the painting area they need to develop and improve the painting line.

Drawing and equipment for the painting area

All technical aspects, overall dimensions of parts, method of applying paints and varnishes and temperature indicators of production processes of painting and drying were also agreed. It also describes the technological processes of the painting and drying chamber of agricultural machinery, its components, assemblies and devices.

It was important for the customer that the equipment:

• carried out heating in the spray booth due to a gas burner (on liquefied gas)
• air ducts for supply and exhaust ventilation, as well as a chimney, must be designed and installed in such a way as not to interfere with the existing crane beam to move along the entire
• length of the workshop;
• the camera should be installed on a flat floor, without foundation work;
• the gate of the camera cabin must have an electric drive and have a remote control;
• the term of the project with installation and commissioning should be as short as possible.

Painting area

Our designers have developed a model of a diagonal spray booth, that is, air is supplied to the booth through a ceiling plenum in the front of the booth, and is extracted through a wall with a filter at the back of the chambers, diagonally across the room. Heating in the painting and drying booth was carried out using a gas burner from the Italian company Unigas. It was decided to install a gate with an automatic, electric drive and remote control from Alutech on this object, installed outside the spray booth. We have made every effort to squeeze in within a short time frame specified by the customer.

Installation of the painting area

Further, installation and commissioning began. The assembly of this chamber, air duct and chimney line went quickly and smoothly. During installation, there were no significant problems or hiccups, which cannot be said about the commissioning work, which presented several surprises. All systems, components and assemblies of the chamber worked perfectly, except for the gas burner. For normal adjustment of the burner for operation from gas cylinders, and not from the main gas pipeline, representatives of the technical department and an electrical engineer selected the correct industrial reducer with regulation of not only pressure, but also gas flow. By installing this reducer and other components in the gas supply system of the burner, it was achieved: excellent operation of the burner with thermal indicators that were quite satisfactory for us and the customer.

Experience of using the complex

The customer has been using the spray booth for less than six months, and is satisfied with the result. It is especially noticeable in the quality of paint and varnish coatings on parts, improvements in working conditions for workers in the painting area, and a decrease in the time spent on manufacturing finished products in general.

In early 2021, VK Avtotransportnyk LLC approached TWEKO for the installation of painting equipment — an Italian TERMOMECCANICA GL painting and drying chamber in Ukraine, measuring 16×5×5 m — as well as the design of ventilation for the painting workshop. After negotiations with several companies, the client chose TWEKO for its professional approach, and we successfully completed the project, ensuring not only high-quality painting of specialized vehicles but also improved personnel safety, consistent results, and optimized coating material costs.

About the Company

VK Avtotransportnyk LLC is a manufacturing complex in Fastiv, Kyiv Region, operating since the 1950s and specializing in the production and maintenance of commercial and specialized vehicles. Since 2019, the company has been producing vehicles under its own AVTR brand, having obtained an international vehicle manufacturer certificate. Its product range includes aerial platforms, truck cranes, vacuum trucks, garbage trucks, emergency repair vehicles, and water transport tanks, including for the Ministry of Defense of Ukraine. The company also provides maintenance, repair, and retrofitting services, offering mobile on-site teams and collaborating with leading brands such as IVECO, RENAULT, and PALFINGER, enabling the use of reliable components. Its clients include Epicentr, Naftogaz, and Interpipe, reflecting its strong market reputation.

The project aimed to ensure high-quality application of coatings on vehicles repaired at the facility. This required the installation of a modern Italian-made painting and drying chamber and the development of an efficient ventilation system. A particular challenge was the lack of a prepared foundation for the equipment, necessitating additional work.

Painting and Drying Chamber

• Spacious working area: 16×5×5 m, making the chamber ideal as a painting chamber for heavy vehicles and large specialized equipment.
• Two zones: separated by gates into 8×5×5 m sections for painting and drying, providing flexibility and process efficiency.
• Reliability: the chamber meets high-quality standards required for professional painting of specialized vehicles.

Design of the Ventilation System for the Painting Workshop

• Thoughtful design: developed considering the workshop’s specifics, maintaining necessary cross-sections and airflow capacity.
• Precision engineering: TWEKO provided detailed drawings, enabling the client to independently manufacture and install air ducts without issues.
• Efficiency: the system ensures optimal air circulation for the chamber’s operation, creating ideal painting conditions.

Project Implementation: Installation of the Painting Chamber and Ventilation

After signing the contract, TWEKO, in collaboration with the client’s builders, developed a foundation work plan, aligning all technical details. During the foundation pouring, our specialists regularly monitored the process, addressing any issues. The installation of the painting equipment was completed ahead of schedule while adhering to all safety standards. A qualified TWEKO engineer conducted commissioning, ensuring flawless operation of the Italian equipment. TWEKO’s design department developed tailored air duct lines, creating optimal conditions for the chamber’s performance. All work was completed ahead of schedule, highlighting the professionalism and coordination of the TWEKO team:

1. The modernized painting workshop of VK Avtotransportnyk LLC meets high-quality standards.
2. Advanced equipment and well-designed ventilation ensure impeccable coating application on specialized vehicles.
3. Precise drawings from TWEKO enabled the client to efficiently manufacture and install air ducts.

Planning to modernize your painting workshop? Contact us for a tailored solution!

Request a Quote

The sales department of our company received a request from representatives of the company “Krug-TET“, which is located in Cherkassy, ​​for the development and manufacture of a painting chamber for two work stations. Purpose – for painting KUNGs, vehicles and accessories for expedition vehicles based on trucks of various sizes. It was decided to manufacture a passage-type camera, which is a great advantage over dead-end cameras.

The painting chamber is retrofitted with gas detectors, which measure the concentration of flammable gases to an explosive state and signal the presence of such a concentration, having several response thresholds. This alarm reacts to fumes and gases from solvents, varnishes and paints from all manufacturers of such materials.

These posts are combined into one painting chamber, but they have 2 completely different ways of using, namely:

• when the gates separating them inside the chamber are closed, the posts work independently of each other, have their own automatics and controls, in turn, I manage the supply and exhaust ventilation systems, as well as heating the paint-and-lacquer coating area (or drying it) independently of each other. This makes it possible to paint several medium-sized items independently of each other with different materials, at different temperatures and at different pressures at each post. Or paint products at one station and dry the painted products at another, thereby saving time in the production process.
  when the gates are open inside the premises, the posts work as one large chamber, the automation system regulates two posts at the same time, which allows painting and drying large-sized items that cannot be accommodated in one post.
• the painting chamber (painting and drying) was designed in such a way that the groups of supply and exhaust ventilation, as well as air heating, were in one room, the camera cabin was in another room, and the controls were in a dedicated room.
  The installation of this camera was carried out according to the planned schedule and in accordance with the contract. The customer prepared the premises, holes in the walls and pits according to the drawings, before the start of work, according to the provided design documentation. The equipment was designed for the customer’s premises so clearly that the distance between the ceiling of the chamber and the ceiling of the existing workshop is only 10 mm.

The installation of supply and exhaust ventilation ducts and chimneys was carried out by materials and specialists of the involved contractor, which was hired by the customer. All work on laying the air ducts was carried out according to the conceptual solution provided and the drawings of our design office.

During the commissioning work, our specialists trained the customer’s personnel in the use of the equipment, the principles of its operation, and safety precautions during the operation of the equipment.

For several months of active operation, the customer’s painters expressed a desire to increase the illumination at the ends and at the bottom of one of the products, which is painted in a large painting station. Therefore, it was decided to modernize the lighting system at this post of the spray booth. For this, all the wishes of the painter, the angle of inclination of the lamp, the location of the product and the height of the working area in which there is not enough lighting for high-quality application of paints and varnishes were taken into account. Specialists of our technical department, design office and production have developed and manufactured side lamps with end caps. They were installed at the corners of the painting station, this position did not reduce the space at the painting station, and completely satisfied the customer’s painters.

At the moment, the equipment is operating normally, the customer is completely satisfied with the equipment and its work, as evidenced by the letter of review.

Gran-Premier LLC, a leader in the production of high-quality wooden interiors, aimed to modernize its grinding and painting facilities to enhance efficiency and improve working conditions. After a thorough search for a reliable supplier, the company chose Techservice VEKO and Partner GmbH LLC, a renowned manufacturer of painting equipment and a market leader with an impeccable reputation in service support.

Collaboration with Techservice VEKO and Partner GmbH LLC began with a detailed discussion of Gran-Premier’s needs. TWEKO specialists carefully analyzed all technical aspects and developed a tailored solution that met the unique requirements of the production process.

Key elements of the modernization project included:

• Design of an exclusive painting chamber: TWEKO engineered a painting chamber perfectly suited for limited spaces with protrusions, providing maximum natural lighting through large double-glazed windows.
• Selection of an aspiration system: To maintain a clean and safe working environment, an aspiration system was selected and installed to effectively remove dust and other contaminants from the grinding area.
• Energy-efficient equipment: The painting chamber is equipped with an electric heat exchanger for cost-effective and environmentally friendly air heating.

In May 2021, the modernized grinding and painting facilities of Gran-Premier were successfully commissioned.

The results of the collaboration with Techservice VEKO and Partner GmbH LLC exceeded all of Gran-Premier’s expectations:

1. Increased productivity: Thanks to the modernized equipment, the production process became significantly faster and more efficient.
2. Improved quality: The new equipment ensures flawless painting and finishing, meeting the highest standards.
3. Safe working conditions: The aspiration system and modern equipment minimize health risks for personnel, creating a healthy and safe working environment.

Gran-Premier LLC gladly recommends Techservice VEKO and Partner GmbH LLC as a reliable and responsible partner in the modernization of industrial equipment. The company highly values TWEKO’s professionalism, tailored approach, and impeccable service.