In February 2021, TDC Ukrspetstekhnika approached Techservice VEKO and Partner GmbH LLC to modernize its painting facility and enhance the efficiency of the painting process. TWEKO proposed and implemented a custom-designed painting and drying chamber, model FРЅ-2.5, which perfectly matched the specifics of the client’s existing premises.

TDC Ukrspetstekhnika, part of the TDC group of companies and an official supplier of leading global brands of specialized machinery, contacted TWEKO to modernize its painting process and create a safe, cost-effective, and productive working environment. The collaboration resulted in a tailored solution for equipping the painting facility, fully meeting the client’s needs and successfully implemented within the agreed timelines.

TDC Ukrspetstekhnika offers a wide range of services, including:

1. In-house production of forklifts, ensuring high quality and reliability of the machinery.
2. Sales of specialized machinery and spare parts from renowned global brands.
3. Professional service and warranty support for all sold machinery.
4. Diagnostics and repair of specialized machinery at modern service centers with experienced specialists.

After a thorough search for a reliable supplier of painting equipment, TDC Ukrspetstekhnika chose TWEKO, a well-known equipment manufacturer with an impeccable reputation and extensive experience.

The project for TDC Ukrspetstekhnika exemplified TWEKO’s effective implementation of a custom solution:

• Custom Design: Specialists from Techservice VEKO and Partner GmbH LLC designed a painting and drying chamber КФ.000.00.00-ENERGY, model FРЅ-2.5, perfectly suited to the existing premises of Ukrspetstekhnika.
• Comprehensive Solution: The chamber includes an exhaust cabinet with dry filtration of used air and supply ventilation with air heating via an electric heat exchanger.
• Quality and Reliability: The chamber is made from high-quality materials and components, ensuring durability and uninterrupted operation.
• Precision Execution: The chamber was manufactured, delivered, and installed within the agreed timelines, fully complying with all contract requirements.

The equipment was manufactured, installed, and commissioned within the specified timelines. During operation, it has proven to be reliable, efficient, and fully compliant with the stated specifications.

As a result of the collaboration, Ukrspetstekhnika received:

1. Efficient Painting Chamber: Thanks to innovative technologies and high-quality equipment, the painting and drying process became significantly faster and more efficient.
2. Clean and Safe Working Environment: Dry filtration of used air and supply ventilation with heating ensure a clean and safe working environment for personnel.
3. Cost Savings: The use of an electric heat exchanger for air heating makes the chamber’s operation more economical.

TDC Ukrspetstekhnika recommends Techservice VEKO and Partner GmbH LLC as a reliable and responsible partner in the supply of painting and drying equipment.

In 2021, TWEKO successfully completed a project’s implementation of a painting facility for Mashhydropryvod LLC, one of the leaders in the Ukrainian hydraulic equipment market. The installed equipment significantly optimized production processes and improved the quality of paint coatings.

Painting Line

In April 2020, the company Mashhydropryvod LLC (MHP) contacted us with a request to supply equipment for painting and drying their products.

After thoroughly analyzing Mashhydropryvod LLC’s technical requirements, we developed and proposed our solution for the layout and equipment composition (painting line). TWEKO’s recommendations allowed us to fully meet production needs and streamline work processes.

Our specialists also calculated and justified the optimal set of technological equipment. This fully meets production requirements and significantly reduces additional work processes on the painting line.

Thanks to the efficient work of the sales department and the productive efforts of our engineers, after lengthy pre-contract negotiations, our company was selected as the supplier and contractor for this project. According to Mashhydropryvod LLC, the specialists from Techservice VEKO and Partner GmbH demonstrated the most rational approach to project implementation. Additionally, TWEKO has its own production facility (located in Kyiv) and a design department, allowing for prompt project adjustments before the contract is signed.

The painting line for MHP included:

Based on the technical requirements, TWEKO developed and supplied a set of equipment:

• Painting chamber KFS.000.00.00-ENERGY (2 sets):
  • Working area dimensions: 4000 × 4000 × 2500 mm.
  • Components: 2 exhaust cabinets with water curtain (2000 × 600 × 2300 mm), supply ventilation with electric heating, high-quality in-house lighting.
• Drying chamber KS.000.00.00-ENERGY (1 set):
  • Working area dimensions: 4000 × 4000 × 2500 mm.
  • Drying temperature: up to 100°C.
• Paint preparation room (1 set):
  • Working area dimensions: 4060 × 4000 × 2500 mm.

Advantages

1. Optimization of production processes through a well-thought-out layout.
2. High-quality paint coating for products.
3. Reliability and uninterrupted operation in intensive mode.
4. Reduced processing time thanks to efficient equipment.

The equipment was manufactured in accordance with all customer requirements, using energy-efficient solutions and high-quality materials.

Implementation

In April 2021, Techservice VEKO and Partner GmbH completed commissioning works, put the equipment into operation, and signed all necessary documents. By October 2021, operating in a three-shift mode, Mashhydropryvod LLC reported no issues, and everything functioned normally.

We invite you to cooperate!

Last year, 2020, we were approached by the customer Kharkiv Design Bureau for Mechanical Engineering named O.O. Morozov with a request to purchase a painting and drying booth (FSK) for painting military equipment and metal structures of its own production. State Enterprise Kharkov Design Bureau for Mechanical Engineering named after A.A. Morozov (SE “KMDB”) is part of the state concern “Ukroboronprom” and is a leading developer and manufacturer of armored vehicles in Ukraine.

AREAS OF ACTIVITY SE “KMDB”:

• development of heavy tracked vehicles (tanks, heavy infantry fighting vehicles, engineering and recovery vehicles);
• development of wheeled vehicles 4×4, 6×6, 8×8, multi-purpose chassis 10×10;
• development and production of complex and tactical simulators on dynamic platforms for any types of armored vehicles;
• development and production of remotely controlled combat modules with weapons of caliber from 7.62 mm to 30 mm;
• serial production of BTR-4E armored personnel carriers and vehicles based on them.

Also civilian products and research activities:

Special machines;
Hydraulic equipment;
Equipment for non-ferrous metallurgy;
Equipment for the fuel and energy complex;
Computational studies, volumetric hydraulic drives,
Stands for testing power plants,
Manufacturing of folding parts.
COMPOSITION OF THE PROJECT

According to the terms of reference, the project included:

Painting and drying chamber with drying temperature up to 90C;
Spare parts kit – spare parts, tools and accessories for FGC for 2 years of operation;
Rail transport trolley on cable traction with built-in tilting device;
Foundation slab with built-in underground air ducts;
Laying of air ducts for FGC;
Connection of energy carriers to FGC;
Installation, commissioning, training of the customer’s personnel and painting of test parts.
Rack-and-pinion rope-drawn transport trolley (RTK)

RTK with a built-in tilting device for moving products into the chamber. The rack-and-pinion transport trolley on a cable traction (hereinafter referred to as the “trolley”) is designed to move products between the working areas of the paint department.

The trolley is a simple, reliable option for delivering parts for processing to industrial paint and sand/shot blast rooms. All electrical installations are removed from premises with an explosive or flammable environment, which allows the use of this type of trolley in category A premises.

Painting and drying chamber

FSK with dry filters is designed for preparation, painting and subsequent drying of surfaces of various products of the plant. The chamber operation processes meet all the demanding requirements for labor protection of workers during painting. The application of the paintwork is carried out by pneumatic manual spraying. Drying of a paint and varnish covering is made at a temperature of 90C!! FGC works on the principle of “dry” filtration of the supplied air using coarse and fine filters made of synthetic materials. This is exactly what the customer needs. The painting and drying chamber consists of a cabin, heat-ventilation units, filters for air purification from harmful impurities, a lighting system, a control panel and other parts.

OPERATING PRINCIPLE OF FGC KMDB

Coloring mode

During the painting process, the air passes through the air intake valve, then enters the pre-filter, then follows through the tidal fan, passes through the heat exchanger, where it is heated, and from there through the ceiling fine filter enters the camera cabin. The air containing paint mist particles is filtered through the floor filter, passes through the ejection damper and is discharged outside with the help of an exhaust fan. The recirculation gate is closed at this time.

Drying principle

The chamber works on the principle of circulation with the partial addition of “fresh” air and dry filtration. The drying mode works offline: the operator needs to set the required drying holding time and temperature. The mode consists of three cycles:

• Purge cycle
• Drying cycle
• Refrigeration cycle

3. Refrigeration cycle

This cycle is necessary to cool the dried product and the heat exchanger unit. After the end of the cycle, the camera automatically stops and goes into standby mode.

CAMERA SPECIFICATIONS

In 2020, the State Enterprise “Kharkiv Design Bureau A.A. Morozov” started a large-scale reconstruction of the painting department. The purpose of the event: To modernize production facilities, improve the environmental standards of their production and improve the quality of the paintwork of their company’s products. The section for painting oversized parts of armored personnel carriers, produced by SE KMDB, needed a new spray booth with a water curtain. Therefore, in order to select an equipment supplier, the customer announced a tender procedure on the official electronic public procurement platform Prozorro.

According to the terms of the tender procedure, the equipment delivery set included:

• Spray booth with a water curtain with dimensions of at least 5000 x 2000 x 2000mm,
• Preparation of the foundation for the installation of equipment,
• railroad laying,
• Installation of conveyors for supplying large-sized parts to the working area in a suspended position. The weight of large-sized parts (which are planned to be hung) is not more than 500 kg.
• Fabrication and installation of exhaust ducts.

Reconstruction of the painting department

Before submitting the tender proposal, the specialists of Techservice VECO and Partner GmbH LLC made a trip to the future, the customers of the State Enterprise Kharkov Design Bureau A.A. Morozov” and studied in detail the existing painting area, the equipment installation site, engineering communications for connecting the equipment, the state of the foundation for installing the equipment, and provided recommendations and several options for laying a rail track, which in the future will carry out the movement of products on the customer’s trolley. Also, our specialists examined small and large-sized parts for painting. The room for the installation of exhaust ducts was inspected

After winning the tender, the already existing equipment at the paint shop (which was manufactured back in the 1970s) was dismantled and disposed of. After that, as part of the contract, the site was prepared for the installation of new equipment, a new rail track was laid, trolleys were installed for moving products and a new spray booth with an efficient water filtration system was installed.

Results

Thanks to the new equipment of the State Enterprise “Kharkov Design Bureau A.A. Morozov” have significantly reduced emissions of harmful substances and increased the speed of applying paintwork to products.

All equipment and works were performed in accordance with the terms of reference and tender documentation, therefore the State Enterprise “Kharkov Design Bureau A.A. Morozov” recommends us LLC “Techservice VECO and partner GmbH” as a reliable manufacturer of equipment for painting areas. As evidenced by the letter of review, which is posted below.

Successful Collaboration with Vektor Kapital Investment Company LLC — Implementation of a Custom Paint Booth Project

At the end of 2018, Vektor Kapital Investment Company LLC approached TWEKO (Techservice VEKO and Partner GmbH LLC), a leading equipment manufacturer known for its impeccable reputation, with a request for a paint and drying booth. After a thorough search for a reliable partner, Vektor Kapital chose us for our expertise and innovative solutions.

The client’s goal was to acquire efficient painting and drying equipment while dealing with limited production space and the inability to install underground exhaust ducts.

Our Solution

TWEKO specialists carefully analyzed the client’s technical requirements and developed a custom solution — a dead-end paint and drying booth with a working area of 7×3.5×2.7 m, tailored to space-constrained production facilities. The booth was installed on a flat outdoor surface, requiring no major construction or additional utilities beyond electricity. This approach significantly reduced installation time and overall project costs.

To meet the client’s specific needs, we delivered a comprehensive solution that combined engineering precision, adaptation to production conditions, and cost optimization. Key elements of this solution included:

• Tailored Approach: TWEKO specialists thoroughly assessed Vektor Kapital’s requirements and proposed an optimal solution adapted to the limited available space.
• Innovative Design: Instead of a traditional booth with underground exhaust ducts, we offered a solution from the AKFS Electro series, model “KFS.000.00.00-Energy,” designed for outdoor installation and requiring no additional construction work.
• Quality and Reliability: The booth is constructed using high-quality materials and components, ensuring long-term durability and dependable operation.
• On-Time Delivery: The booth was manufactured and installed within the agreed timeline, fully meeting all contractual obligations.

The paint and drying booth was manufactured, installed, and commissioned in May 2019. Since then, it has been operating reliably, delivering efficiency and high-quality finishes in the client’s production process.

Client Benefits:

1. Accelerated and enhanced painting and drying performance through advanced technology.
2. Space savings by utilizing outdoor installation, freeing up indoor production areas.
3. Cost savings due to efficient electric heating.
4. Long-lasting performance and reliability thanks to premium-quality materials.
5. Streamlined installation with no need for additional utility connections.

As a result of this project, Vektor Kapital received a fully customized solution that met all expectations in terms of quality, deadlines, and technical specifications. The professionalism of the TWEKO team, well-organized execution, and commitment to contractual obligations earned a positive review:

This successful experience highlights how the right partnership can significantly boost your production efficiency.

This case demonstrates that choosing a reliable partner is the key to success. TWEKO (Techservice VEKO and Partner GmbH LLC) delivers innovative, high-quality, and cost-effective solutions tailored to your business.

In 2021, TWEKO completed a project to supply and install a painting and drying complex for the V.O. Malyshev Plant, a leading Ukrainian manufacturer of specialized military equipment. The complex significantly enhanced the efficiency of painting processes and the quality of product finishing.

In September 2020, the V.O. Malyshev Plant announced a tender for the supply of a painting and drying complex as part of the enterprise’s technical re-equipment program. The technical specification, approved by the chief engineer, outlined a full project cycle: design, manufacturing, delivery, installation, and commissioning.

In accordance with Ukrainian legislation, an open tender procedure was conducted. Based on its results, our company, Techservice VEKO and Partner GmbH, was selected as the winner. The client’s decision was based on our proposal’s compliance with all technical requirements and TWEKO’s reputation as a reliable supplier of comprehensive solutions.

Our competitive edge is driven by in-house production, experienced sales, design, and service department specialists, enabling prompt responses to project challenges and the implementation of changes at all stages. A comprehensive approach to design and flexibility in decision-making make TWEKO a trusted partner for technically complex and large-scale projects.

Project

The project for the V.O. Malyshev Plant is one of the most ambitious and technically challenging in our company’s portfolio. It involved not only the supply and installation of technological equipment but also a range of preparatory construction and installation works, laying a rail track, and setting up engineering utilities. A particular challenge was the development and manufacturing of a custom drying chamber capable of drying large and heavy products at temperatures up to 150 °C — the first of its kind implemented by our company.

Works and Equipment

Under the contract terms, TWEKO carried out:
1. Construction Works:

• Preparation of the floor and ventilation ducts for the painting chamber.
• Floor setup for the drying chamber.
• Laying a rail track and installing a traction winch.
• Manufacturing and installation of air ducts for air supply and exhaust.

2. Equipment Manufacturing and Installation:

• Painting and drying chamber with dimensions (L × W × H) — 11160 × 5660 × 5540 mm.
• Drying chamber with dimensions (L × W × H) — 9240 × 4740 × 4075 mm, drying temperature up to 150 °C, heated by electric heat exchangers.
• Rail transport cart with dimensions 6000 × 2300 × 1100 mm, load capacity of 15 tons.

The successful implementation of this project marked a significant milestone in TWEKO’s development. It allowed our team to gain invaluable practical experience and expand the company’s technical and production capabilities. Each new project enables us to raise the bar even higher.

Advantages

1. High-quality paint coating due to state-of-the-art equipment.
2. Optimized painting processes through a well-designed complex.
3. Reliability and compliance with stringent military production requirements.
4. Effective collaboration at all project stages.

TWEKO completed the full scope of work — from equipment manufacturing to installation and commissioning — with high quality and within the stipulated timelines. Specialists from the design and service departments promptly made necessary adjustments to the project in coordination with the client, ensuring compliance with the technical specifications and tender conditions.

Conclusion

This large-scale project is further proof that TWEKO can handle the most complex technical challenges at the highest level. We are ready to support any enterprise striving for technological advancement.

In 2018, the sales department of our company received a request for a painting and drying chamber and an abrasive blasting chamber from representatives of ZLMZ LLC. In the course of negotiations, lasting a year, we, together with ZLMZ, formed the terms of reference and drew up a detailed plan for the construction of the painting area as a whole. To implement this project, it was necessary, first of all, to carry out work on the design of a new paint area at the enterprise, to coordinate the project with local authorities, to conduct an environmental impact assessment, while observing the strictest fire safety rules…

The next stage after the design was the implementation of construction and installation work – it was necessary to dismantle a concrete base up to 1.5 meters deep, and then equip a foundation slab for installing equipment with built-in technological pits for ventilation and equipment operation, a rail track for supplying products to the working areas of the chambers…

The painting area of ​​production is a rather energy-intensive area. Since to ensure high productivity and safe working conditions, it is required to provide a colossal airflow in the painting chamber – up to 100,000 cubic meters/hour, while heating the air to a delta of 35 ° C in painting mode and up to + 80 ° C in drying mode – such a spray booth, with electric air heating, consumes up to 500 kW/h of electricity. The abrasive blasting chamber consumes up to 12 cubic meters/min, 8 atm, compressed air while consuming up to 50 kW of electricity per hour. The total energy consumption of the painting area reaches 700 kW/h. Naturally, to provide such a volume of electricity, it was necessary to lay a separate power transmission line from the TP, with a length of 240 meters, and this was also included in the scope of work performed by our company within the framework of this project.

The scope of delivery of the equipment included: a painting and drying chamber, an abrasive blasting chamber, two self-propelled rail carts, abrasive blasting machines, airless high-pressure painting machines, a compressor room with receivers and air dryers, a set of lifting-mobile platforms for painting large-sized items, a cabin for storage and making paints…

Paint area

A painting and drying chamber and a dead-end type abrasive blasting chamber are located outside the main production area, adjoining it with a front wall with a gate. Both chambers have an internal size of 16180x6000x5500 millimeters, and together with rail trolleys, they can efficiently handle products with dimensions up to 15000x4000x5000 millimeters and weighing up to 20 tons! Both chambers have excellent energy efficiency, as they are hermetically sealed and made of sandwich panels with a fireproof filler – mineral wool, 100 mm thick. The spray booth has three rows of sealed energy-efficient LED lighting fixtures that provide at least 800 lux of illumination inside the cab, which allows for the best possible paint application on a wide variety of products.

A set of lifting-mobile platforms built into the spray booth allow operators to move quickly inside the booth and handle products up to 6 meters high. The platforms move in three directions – along the entire length along the walls of the chamber, along the entire height of the chamber, as well as from the wall at a distance of up to 1500mm. The platforms are driven by compressed air, which makes them explosion-proof and can be used in a spray booth environment.

The abrasive blasting chamber (KASO) has a system for the automatic collection and regeneration of shots and debris. The scraper floor system is responsible for collection and transportation, which consists of five longitudinal and one transverse line, which moves the shot to the elevator pit with synchronous translational movements. Further, the elevator raises the shot to a height of 7 meters, from where it enters the drum-type separator. In the separator, the shot is sifted and cleaned of large contaminating particles, and fine dust is removed through the dust extraction channels to the filter unit. After passing through the separator, the shot automatically enters the storage hopper in which the abrasive blasting machines are arranged. Thus, the abrasive blasting chamber provides a fully automatic collection, regeneration, and supply of shots for reuse – a closed cycle. The dust removal system is responsible for ensuring safe and comfortable working conditions in KASO, which is represented by two highly efficient filter and ventilation units FVU-18, they promptly remove the dusty gas-air mixture from the chamber, filter it and release it into the atmosphere.

The compressor station is represented by a high-performance screw compressor Remeza VK120, with a productivity of up to 16,000 liters per minute at 8 atmospheres of pressure, and effective installation with an air dryer – freezer, 4 compressed air receivers with a volume of up to 1000 liters each.

The set of equipment includes the Wiwa Airless 140032 RS/F Phoe Airless Painting Machine, the CLEMCO SCWB Shot Blasting Machine – 2452, 200 liters. with a full set of operator’s suit and personal protective equipment. And to ensure fire safety, the painting area is equipped with an automatic powder fire extinguishing system, fire alarm, and its connection to local fire extinguishing services.

Probably, the production of equipment was not the most difficult in the implementation of this project, it was much more difficult to correctly draw up the terms of reference, carry out the design, design development, coordinate all the processes and stages of implementation: construction, laying communications, fire safety… At the same time, observing the strictest security rules labor that operates at the enterprise LLC “ZLMZ”, PJSC “Zaporizhstal” and throughout the Metinvest Holding. And also find reliable contractors, coordinate and organize their work, plan everything and invest in the schedule.

This project gave our company invaluable experience in the implementation of a difficult and complex object, moreover, for one of the largest enterprises in Ukraine – Metinvest Holding! The implementation of such a project once again confirms the ability of our company to create and implement the most complex technological complexes for the painting department of any, even the most demanding Customer.

In 2020, TWEKO modernized the painting workshop of the private enterprise VKP Alfateks, an official dealer of OJSC MAZ in Kremenchuk, by supplying a painting and drying chamber to enhance the quality of coatings on finished products, components, and assemblies.

Objective

The project aimed to improve the quality of applying coatings to finished products, components, and assemblies. After analyzing needs with technical specialists, the production manager, and painters, it was decided to procure equipment with:

• High-quality coating application.
• Efficient air purification and rapid heating.
• Exterior in the company’s branded colors.
• Dimensions of 13,500 × 5,500 × 5,000 mm.

TWEKO was selected among competitors for its optimal solutions and flexibility after market research and evaluation of commercial proposals.

Implementation

After signing the contract for supply and installation, the painting and drying chamber model KFS.000.00.00.-ENERGY “G” was manufactured in accordance with the agreed timelines and quality standards. The equipment installation was carried out promptly and in compliance with all safety regulations. The air supply and exhaust system was partially installed by the client based on TWEKO’s provided drawings, ensuring seamless integration. Comprehensive setup of the air supply and exhaust system was successfully completed, providing optimal conditions for the painting chamber’s operation.

Benefits for the Client

The client highlighted:

1. Powerful airflow and high air purification.
2. Rapid heating and precise temperature control.
3. Reliable operation with regular maintenance.

The modernization of the painting workshop was a successful step for VKP Alfateks, enabling improved product quality and equipment reliability. VKP Alfateks received equipment that operates properly and ensures high-quality coatings.

At the end of February 2020, we received a request for a set of equipment including a painting and blasting booth for metal structures. The production base of the customer’s company is located in the city of Mariupol, Donetsk region. Thanks to a lucky coincidence, our specialists were nearby, in the city of Zaporozhye, promptly responded to the request and went to the customer’s site.

The customer company Azovtekhgaz LLC is engaged in the supply of technical gases, gas mixtures and gas welding equipment, as well as in construction and installation works in various areas of industrial construction. The maximum overall size of products to be processed in chambers is 12x3x3m. Shot-blasting and painting chambers will improve the quality of the paintwork of all metal products manufactured by the company.
The spray booth has two main modes of operation – painting and drying, with operating temperatures of 18-24 C and 20-70 C, respectively. The passage-type chamber has an internal size of 15x5x5m, two sets of sectional doors with an automatic drive are installed in the end walls. The air is heated using three high-performance gas burners, each with a power of up to 350 kW, and stainless steel heat exchangers, designed and manufactured by our company specifically for spray booths. Two side and two ceiling rows of high-performance four-lamp LED luminaires are responsible for lighting in the spray booth, while the illumination level inside the booth is at least 900 lux.

Azovtekhgaz

The main feature of this spray booth model is that it has the ability to work in zones. Three separate thermo-ventilation cabinets, in combination with a specially developed automation and control system, allow you to turn on and operate each zone separately from the rest. Thus, the camera has three zones 5x5x5m, and when painting oversized products, camera operators can use only one or two of the zones. Automation and control systems in this design are three times larger, more expensive and more complex than usual, but due to this, when operating the camera, the costs of electricity and natural gas are significantly reduced!
The abrasive blasting chamber has an internal size similar to the spray booth – 15x5x5m. The chamber has a sealed cabin made in the form of a prefabricated steel structure with sandwich panels. The inside of the cab is lined with an elastic soft material that protects the steel structures of the cab from damage by ricochet shots. The camera is illuminated by two rows of ceiling, located at an angle of 45 °, four-lamp LED luminaires, protected from possible mechanical damage by ricocheting shot. The chamber quickly and effectively cleans the dusty air that forms during the cleaning process; for this, it is equipped with a FVU-30 filter ventilation unit. FVU-30 is one of the models of filtering units developed by our company, it has a productivity of 30,000 cubic meters per hour, 30 cylindrical dust filters and an automatic filter cleaning system.
The blast chamber is equipped with systems for automatic collection and regeneration of abrasive material, dust and debris removal. There are special pits in the foundation of the chamber, which are covered with steel gratings. Shot and debris generated during cleaning is poured into these pits. During operation, they are automatically collected by scrapers and directed to the bucket conveyor pit. The scraper floor is driven by reliable electric drives, which guarantees a long and trouble-free operation of the entire system. After that, the shot that got into the pit of the bucket conveyor rises and goes to the shot regeneration unit – a vibration-type separator. The vibrating separator automatically separates the incoming material into three parts: the debris and impurities are discharged into the debris tank, the dust is discharged to the filtration unit, and the recyclable beads are automatically returned to the shot blasting machine. Thus, in the abrasive blasting chamber, a closed cycle of shot movement is created, while the collection and regeneration of the shot is carried out in a fully automatic mode. All parts and assemblies of the abrasive blasting chamber – FVU, scraper floor, bucket conveyor, vibratory separator are developed by our company specifically for use in abrasive blast chambers, are manufactured at our own production site in Kiev and have an increased degree of reliability and effective protection from damage.

TWEKO implemented a project to equip the body repair department of Bosch Auto Service “VB Avto” (Kosiv, Ivano-Frankivsk region) with a modern car paint booth. The solution includes an AKFS series spray booth and two APP-Standart preparation stations, creating a complete automotive refinishing system for surface preparation, painting, and drying. The equipment is installed on steel platforms with grated flooring, allowing the paint shop to be integrated into the existing service facility without constructing underground ventilation ducts.

About the Client

Bosch Auto Service “VB Avto” is an automotive service center located in Kosiv (Ivano-Frankivsk region, Ukraine) and part of the international Bosch Car Service network. The company has been operating since 2008 and specializes in vehicle diagnostics, maintenance, and repair for various car brands.

As the body repair department expanded, the company decided to establish a modern paint shop equipped with a professional car paint booth capable of ensuring consistent quality for surface preparation, painting, and drying processes.

A key requirement of the project was the integration of the equipment into the existing production facility without extensive construction work.

Project Objectives

The TWEKO engineering team was tasked with designing a compact and efficient automotive paint shop capable of providing a complete vehicle refinishing process.

• organize the technological process for vehicle preparation, painting, and drying;
• enable simultaneous preparation of two vehicles;
• integrate the equipment into the existing building without constructing underground ventilation ducts;
• ensure efficient removal of dust and paint overspray;
• provide safe and comfortable working conditions for personnel;
• optimize vehicle movement between preparation and painting areas.

To achieve these goals, a comprehensive solution based on the AKFS-9 spray booth and two APP-Standart preparation stations was developed.

Solution

TWEKO engineers proposed an integrated automotive painting system consisting of the AKFS-9 spray booth and two APP-Standart preparation stations. This configuration forms a complete car paint booth solution with controlled airflow, lighting, and temperature conditions.

The equipment is installed on steel platform structures approximately 400 mm high with grated flooring. This design enables air extraction through the floor without the need for underground ventilation channels.

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tweko-001_storinka_06[1]

A vertical Down Draft airflow is created within the working zone: filtered air enters through ceiling filters, passes through the spray area, and is extracted through the grated floor together with dust and paint overspray.

The two preparation stations allow simultaneous sanding, filling, priming, and polishing of two vehicles before they are transferred to the spray booth for painting.

Key Components of the System

Technical Specifications

Project Implementation

The project was carried out in several stages and included engineering analysis of the facility, development of the paint shop layout, equipment manufacturing, installation, and commissioning. All stages were completed by TWEKO specialists in cooperation with the Bosch Auto Service “VB Avto” team.

The paint shop system was commissioned in May 2020.

Operating Principle

Vehicle preparation is carried out at the APP-Standart preparation stations, where the vertical airflow system efficiently removes sanding dust and contaminants from the working zone.

After preparation, the vehicle is moved to the AKFS-9 spray booth. During the painting process, the Down Draft ventilation system ensures a uniform distribution of filtered air and effective removal of paint overspray.

During the drying cycle, the diesel-fired air heater warms the circulating air inside the booth, providing uniform curing of the automotive coating.

Video demonstrating the operation of the paint shop at Bosch Auto Service “VB Avto” (Kosiv), equipped with the AKFS-9 spray booth and APP-Standart preparation stations by TWEKO.

Maintenance and Safety

The filtration elements have a modular design and can be quickly replaced during scheduled maintenance. A pressure monitoring system alerts operators when filters require replacement.

The automated control system monitors temperature, pressure, and operating modes. Safety is ensured by temperature sensors, pressure switches, thermal relays, and automatic circuit breakers.

Results

• Complete body repair cycle within a single paint shop.
• Higher productivity due to simultaneous operation of two preparation stations.
• Consistent coating quality ensured by a controlled airflow environment.
• Reduced construction costs thanks to the steel platform installation system.
• Improved working conditions for painters.

Conclusion

The project for Bosch Auto Service “VB Avto” demonstrates TWEKO’s capability to deliver comprehensive engineering solutions for automotive service facilities. The AKFS-9 spray booth combined with APP-Standart preparation stations created an efficient automotive paint shop with reliable performance and high coating quality.

Get a Consultation

At the beginning of 2020, we were approached by the company PE PKP “Eurostal-Komsomolsk”, which is located in the town of Gorishnye Plavni, Poltava region, to supply equipment to the painting site of its production. The reason for choosing our company was that we have been working in the equipment market for more than 25 years, we have many customers who manufacture such equipment, as well as the availability of quality service support.

Green painting and drying chamber

This customer needed a drying and drying chamber with dry filtration, industrial type, electric heat exchanger, automatic gates with remote control, and most importantly – the color of the camera should be exclusive (green), according to the corporate style of the customer.

Unique design and color of the camera

Our specialists from the design department developed a painting and drying chamber, directly for this customer, with installation on a flat floor, a hood in the end wall and a supply ceiling plenum at the beginning of the chamber. This arrangement of clean air supply and exhaust air allows you to paint large products and three-dimensional metal structures as efficiently and quickly. The overall dimensions of the working area of ​​the camera cabin are 9000x5000x5000 mm. The electric heat exchanger used by our designers at this facility was designed to give off the maximum amount of heat, for quick access to the specified temperature modes of painting and drying. This solution allows our customer to maximize the production of quality finished products.

Production

After concluding a contract for the manufacture and supply of equipment, our production began to manufacture this order. Production times were as short as ever, so we had to work even on weekends. The head of production made every effort to ship the painting and drying chamber within the period specified in the contract for the manufacture and supply of equipment.

Installation for commissioning

After the equipment was shipped, work began on assembling the painting and drying chamber on the customer’s territory. During the installation process, the most difficult thing was to connect the camera cabin with the existing room, but our installation team did the job perfectly. It was decided by the customer to produce air supply and exhaust air ducts independently, involving a contractor. The rest of the installations were carried out without delay. After installation, commissioning and training of personnel on the operation and maintenance of equipment were carried out.

The camera is currently working normally!

TWEKO successfully implemented a painting area modernization project for a leading Ukrainian manufacturer of stainless steel heated towel rails and premium design radiators. Based on a preliminary technical design, a comprehensive turnkey solution was developed, manufactured, and commissioned — a semi-automatic pass-through paint and drying complex.

The result is a modern continuous production line with a complete cycle of surface preparation, coating application, and polymerization, ensuring consistently high coating quality and compliance with the requirements of a certified ISO 9001 quality management system.

About the Client

Mario is one of the leading Ukrainian manufacturers of premium stainless steel heated towel rails and design radiators. The company has been operating since 1998 and runs its own modern production facility in Lityn, Vinnytsia region. Mario operates a full-cycle metalworking process and maintains a quality management system certified in accordance with ISO 9001:2015.

In 2018–2019, the company actively expanded its production capacity and broadened its range of decorative coatings. This required achieving 100% color repeatability and coating stability, reducing energy consumption, and optimizing the logistics of the painting area while minimizing the impact of the human factor.

To address these challenges, Mario selected TWEKO as the sole contractor for the design, manufacturing, and commissioning of a complex specifically adapted to the actual operating conditions and dimensions of the existing production facility.

Project Objectives

In 2019, Mario assigned TWEKO a comprehensive task — to design, manufacture, and implement a modern pass-through paint and drying complex for the complete cycle of surface preparation, application, and polymerization of decorative paint coatings on heated towel rails and design radiators. The complex had to be fully adapted to the company’s existing production areas and ensure the processing of products with dimensions up to 1,860 × 800 × 350 mm and a weight of up to 10 kg.

Key customer requirements:

• to develop and approve a technical solution taking into account the actual product dimensions and the existing production area;
• to ensure a complete process cycle: semi-automatic degreasing + rinsing → intermediate drying → electrostatic application of water-based enamels → polymerization at 150–180 °C for up to 20 minutes;
• to integrate four technological zones into a single continuous pass-through process flow;
• to implement an overhead endless-type conveyor system with manual movement and 360° rotatable carriages;
• to maintain a temperature range of +18…+24 °C in the working zones while optimizing energy consumption.

Solution

Based on the approved preliminary technical design, TWEKO developed, manufactured, and commissioned a customized pass-through paint and drying complex, fully adapted to the limited space of Mario’s operating production workshop.

The complex consists of four main technological modules and two auxiliary zones, integrated by a single overhead conveyor system

Transport System▼

An overhead endless-type conveyor system with manual movement ensures continuous transfer of products through all technological zones of the complex. The system includes:

• 12 rotatable carriages with a 360° rotation mechanism, enabling uniform coating of products from all sides;
• five accumulation transfer carriages each in the loading/unloading and drying zones.

The conveyor system was designed taking into account product dimensions (up to 1860 × 800 × 350 mm), weight of up to 10 kg, and specific suspension hook fixing methods. The design allows changes in carriage travel direction and geometric adaptation to the actual shop-floor layout.
Monorail sections are implemented as single or dual parallel profiles (500 mm center-to-center distance), depending on the zone.

The transport system utilizes European-made components (rails, rollers, carriage assemblies), ensuring long service life, smooth movement, and minimal maintenance requirements.

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All zones are interconnected by a single overhead conveyor system. Manual transfer of products between operations is eliminated.

Each technological zone is equipped with a dedicated supply-and-exhaust ventilation unit (AHU). The ventilation system was designed with clearly defined connection points, enabling rapid completion of preparatory works by the Customer.

The total installed power of the complex is up to 140 kW in cyclic operation.

The result is a compact, energy-efficient production line with full process parameter control, stable coating quality using water-based enamels, and compliance with ISO 9001 requirements.

Project Implementation

Based on the product nomenclature, operating conditions, and paint material specifications, a preliminary technical design was developed, including process analysis, preparation of engineering documentation, and planning of equipment layout.

Manufacturing of the complex was carried out at TWEKO’s production facility in Kyiv using components from leading European manufacturers (Pedrollo, Camozzi, Omal, ETI, Rockmin). The modular design allowed adaptation of the system to the actual production space.

Equipment delivery was performed on DDP terms, while preparation of the civil works (foundations, air ducts, and utility connections) was performed by the customer. Following installation and commissioning, the complex was integrated into the existing production facilities as a pass-through technological line.

TWEKO specialists conducted personnel training and handed over a complete set of technical documentation covering the mechanical, electrical, and ventilation systems of the complex.

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Operating Principle of the Complex

The entire technological process is arranged as a pass-through system with manual transfer of products along an overhead endless-type conveyor:

1. Loading — the product is suspended on a rotatable carriage (360° rotation).
2. Degreasing and rinsing — automatic flood-type spray treatment with a heated alkaline solution followed by rinsing with demineralized water in a semi-automatic KMP washing chamber (two stages).
3. Intermediate drying — intensive drying with heated, purified air in a zone equipped with an active floor and supply-and-exhaust ventilation.
4. Painting — electrostatic application of water-based enamel in a pass-through paint booth with a water curtain and hydrofilter (air exchange rate up to 200 air changes per hour).
5. Quality control — visual inspection of the coating and, if required, local touch-up.
6. Polymerization — the final stage, performed in an electric convection curing oven, model PP-3M. The oven operates in three automated phases:
   • Preheating — after pressing “Start”, the heaters and convection fan are activated, bringing the oven to the preset temperature T.
   • Polymerization — temperature is maintained at 150–180 °C for time t₁; the heaters operate in pulsed mode to ensure stable thermal balance.
   • Ventilation — upon completion of polymerization, volatile by-products are actively removed: heating is switched off, while the convection and exhaust fans operate for time t₂.

   After completion of the cycle, the oven automatically switches to standby mode and emits an audible end-of-cycle signal.

7. Unloading — cooling and removal of the finished product.

The complex is equipped with automated monitoring of temperature, solution levels, pressure, and air exchange in all key zones. Manual carriage movement ensures high flexibility for different product types and batch sizes.

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Project Results

In early 2020, the paint and drying complex was successfully commissioned for industrial operation at Mario’s production facility in Lityn, Vinnytsia region.

All key objectives defined by the Customer back in 2019 were fully achieved:

• Stable and repeatable coating quality ensured by controlled parameters at every stage (temperature, polymerization time, and uniform application in the electrostatic field).
• Complete technological cycle within a single pass-through flow — from degreasing to unloading of finished products, without manual transfer between operations.
• High environmental compliance:

  ◦ exhaust air purification efficiency ≥ 97% (water curtain + hydrofilter);

  ◦ recirculation and filtration of process solutions;

  ◦ use of water-based enamels.

• Energy efficiency and operator comfort — maintenance of working zone temperatures at +18…+24 °C and a 200-fold air exchange rate in the painting zone.
• Production flexibility — manual movement along the overhead conveyor and rotatable carriages (360°) enable rapid adaptation to different types and sizes of heated towel rails and design radiators.
• Reliability and serviceability — modular design and European-made components (Pedrollo, Camozzi, Omal, ETI, Rockmin) ensure long-term, trouble-free operation.
• Personnel safety — automated washing and drying processes, local exhaust ventilation, sensors, and interlock systems.

The complex has been operating in standard production mode since 2020 and is fully compliant with the company’s certified ISO 9001 quality management system.

Conclusion

The implemented production line for Mario represents a modern, environmentally friendly, and flexible solution that delivers consistently high-quality decorative coatings using water-based enamels and provides effective air purification (≥97%). The complex meets ISO 9001 requirements, optimizes energy consumption (approx. 140 kW in cyclic operation), and has been operating reliably since 2020.

This modernization project clearly demonstrates TWEKO’s expertise in developing energy-efficient technological solutions for applying decorative coatings to stainless steel products. The TWEKO team is open to implementing similar projects and to further long-term cooperation.

Do you need predictable decorative coating quality on stainless steel without rework or color variation?

TWEKO painting complexes ensure a controlled microclimate in the painting zone and environmentally compliant exhaust air purification. Each system configuration is fully adapted to the specific parameters of your production facility.

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