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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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.

Request a Quote

In late July 2019, State Enterprise “Specoboronmash” approached TWEKO with a request to build a paint booth with a water curtain for their paint shop. The TWEKO team designed, manufactured, and commissioned a water-filtered system consisting of two exhaust booths and a supply ventilation unit with diesel heating. The project was completed in October 2019, delivering safe working conditions for applying paint coatings to large metal defense components.

About the Client

State Enterprise “Specoboronmash,” Branch No. 1 of the Ukroboronprom concern, located in Zhytomyr region, specializes in manufacturing and servicing defense equipment. The enterprise has very high safety and quality standards for its production processes. In 2019, TWEKO partnered with them to modernize their paint shop, establishing a productive collaboration.

Project Objective

The goal was to create safe working conditions in Specoboronmash’s paint shop. The primary requirements included:

• A paint booth with water filtration to effectively remove paint fumes.
• A supply ventilation system with air heating to provide a comfortable working environment.
• Design adaptation to budget constraints and classified facility requirements.
• Project completion within tight deadlines—from August to October 2019.

Solution Provided by TWEKO

TWEKO proposed a tailored solution, considering budget constraints and safety demands:

• Exhaust booths with water curtain. Two booths sized 2000×600×1900 mm and 4000×600×1900 mm provide efficient paint fume filtration using a water curtain.
• Supply ventilation system with heating. A ceiling-mounted plenum (7000×4000 mm) equipped with a heat exchanger and diesel burner ensures warmed air supply. The heated ventilation cabinet was installed outside the facility to meet fire safety standards.

The system is supplemented with an automated control system ensuring stable operation per technical specifications.

Implementation Process

Specoboronmash’s request arrived in late July 2019. After analyzing the shop conditions and technical constraints (such as boiler location and capacity limitations), TWEKO recommended using a diesel burner instead of a water heater. In August 2019, the customer approved the commercial proposal, and manufacturing began. Installation of exhaust booths and the supply ventilation system was completed by October 2019. The equipment was adapted to the classified facility, and the ventilation cabinet was placed outside to enhance safety.

Results for the Client

• Efficient paint fume removal thanks to water-based filtration.
• Comfortable working conditions enabled by heated supply ventilation.
• Compliance with fire safety regulations due to external placement of the heated ventilation cabinet.
• Cost optimization by adapting the solution within budget.

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Client Feedback

Conclusion

The project was successfully implemented on schedule, equipping Specoboronmash with a modern paint booth featuring water filtration. TWEKO demonstrated flexibility in solving technical challenges and compliance with high safety standards.

TWEKO’s Modern Solution: FPH Paint Booth

For similar tasks, TWEKO offers the FPH paint booth with water filtration. This model ensures high-quality air cleaning via a water curtain, creating safe conditions for painting. FPH is ideal for industrial facilities requiring top-tier quality and safety compliance.

Planning to purchase a paint booth with a water curtain? Contact us today to get the price!

Request a Quote

In 2019, TWEKO completed a project for the supply and installation of two ventilation chambers for PJSC Ukrnafta, Ukraine’s leading oil and gas company. The technological booths ensure safe working conditions during equipment cleaning with solvents, meeting stringent explosion-proof and comfort requirements.

In 2019, Techservice VEKO and Partner GmbH won a tender announced by PJSC Ukrnafta for the supply of two ventilation chambers for cleaning specialized equipment. The order pertained to the company’s division located in Pryluky, Chernihiv Oblast.

The purpose of the procurement was to equip technological booths with effective ventilation for the safe cleaning of stators, ESP shafts, and other equipment using solvents. Our company was selected due to its extensive experience in manufacturing industrial ventilation systems in Kyiv and the high quality of its implemented solutions.

Project Implementation

From March to June 2019, TWEKO manufactured and installed two identical ventilation chambers for PJSC Ukrnafta. The equipment was created in full compliance with the technical specifications, all agreed deadlines were met, and it fully satisfied the enterprise’s needs. The chambers provide uninterrupted ventilation and safety, confirming the reliability of TWEKO’s solutions.

Each ventilation chamber has internal dimensions of 12,000 × 4,000 × 2,800 mm and is designed in an explosion-proof configuration (Category A for explosion and fire hazards, climatic modification UHL 4 per GOST 15150-69). The chambers are intended for the effective removal of solvent vapors, petroleum products, and chemicals during industrial operations.

Key features of the technological booths:

• Thermo-ventilation cabinets: Provide the supply of clean atmospheric air, its purification, heating, and exhaust of used air from the chamber.
• Airflow: A constant speed of 0.3 m/s from the front to the rear of the chamber quickly removes vapors, creating safe working conditions.
• Heating: In cold seasons, air is heated by superheated water circulating in 257 kW water calorifiers, with temperature regulation via a control panel within +18–20°C.
• Safety: An automatic system for detecting and removing explosive vapor concentrations ensures worker protection.

Technological Features

These technological booths are sealed chambers with enhanced ventilation and air filtration. The ventilation system ensures the rapid removal of solvent vapors, petroleum products, and chemicals during cleaning. Thanks to constant and uniform ventilation, the chambers create safe and comfortable working conditions for personnel, compliant with European occupational safety standards.

Clean and heated atmospheric air is continuously supplied to the ventilation chamber. The air is heated to +20°C using water calorifiers. Air is supplied through ventilation ducts located at the front of the chambers, while exhaust air is extracted through filter cassettes at the rear. This creates a constant longitudinal airflow at 0.3 m/s, ensuring rapid vapor removal and safe working conditions.

The ventilation chambers have internal dimensions of 12,000 × 4,000 × 2,800 mm. The front wall features insulated swing gates with a 3,200 × 2,400 mm opening. Thermo-ventilation cabinets are positioned at the rear of the chambers. The supply ventilation units have a power of 7.5 kW, and the exhaust units have 5.5 kW, guaranteeing efficient air circulation in the technological booths.

All chamber components—including lighting, ventilation units, and electric motors—are designed in an explosion-proof configuration per Category A requirements. The lighting provides uniform illumination of the work area, and the fan motors have appropriate protection classes, ensuring safe operation even in explosive conditions.

Advantages

1. Explosion-proof design for working with solvents in ventilation chambers.
2. High ventilation efficiency with an airflow of 0.3 m/s.
3. Comfortable working conditions due to adjustable temperatures of +18–20°C.
4. Reliability and compliance with the technical requirements of the oil and gas sector.

Conclusion

The 2019 project for PJSC Ukrnafta demonstrated TWEKO’s ability to develop and manufacture specialized industrial ventilation equipment, particularly for the oil and gas industry. Over four months, two ventilation chambers were produced and installed, reinforcing our reputation as a reliable partner.

The main challenge of the project was the stringent explosion-proof requirements for all chamber components—Category A, climatic modification UHL 4 per GOST 15150-69. Therefore, all elements, including lighting, ventilation units, and electric motors, were designed to meet the necessary protection standards.

We are proud of our successful collaboration with an industry leader and are ready to implement similar solutions for other industrial enterprises.

In 2019, Techservice VEKO and Partner GmbH LLC successfully completed a project to design and install a dead-end type painting and drying chamber for USP Automotive Ukraine LLC. The quality of the supplied equipment and the high level of contractual obligation fulfillment are confirmed by a positive feedback letter from our reliable partner, USP Automotive Ukraine LLC.

At the end of 2018, USP Automotive Ukraine LLC approached us with the need to purchase a painting and drying chamber for test painting of various components. USP Automotive specializes in the sale of professional painting products, including coatings, piston compressors, tools and tool carts, screw (rotary) compressors, high-pressure equipment, jacks, presses, cranes, pneumatic tools, spray guns, accessories, and consumables for painting facilities.

In 2019, specifically in early February, Techservice VEKO and Partner GmbH LLC designed, manufactured, delivered, installed, and commissioned a dead-end type painting and drying chamber (PDC) “KFS.000.00.00-Energy 14” in accordance with the signed contract. The chamber was installed in a small space with numerous protrusions and columns. A diesel burner was selected for air heating in the chamber. The chamber is mounted on a metal podium, with a working area of 4,000×3,500×2,700 mm.

Technical Specifications of the Painting and Drying Chamber

If you need a painting chamber, contact us! With 30 years of experience in the Ukrainian market, we will develop the best chamber option tailored to your needs! Thanks to our in-house production, dedicated design department, top-quality components, and the professional approach of our specialists, we guarantee the long-lasting and reliable performance of our products! We elevate the quality of painting work to a new level!

Planning to purchase a painting chamber for test painting of various components? Contact us today to request a quote!

Request a Quote

For the modernization of the painting department at PrJSC “Ob’iednannia Prohres”, TWEKO delivered an open-type two-zone water wash spray booth with a 4500×4500 mm working area. The system includes two water wash exhaust units, an integrated water-flooded floor system across the entire painting area, and a separately installed supply thermo-ventilation unit (TVU) equipped with a 60 kW electric heating section. The solution provides controlled vertical airflow, stable air exchange, and compliance with fire and electrical safety regulations.

About the Client

PrJSC “Ob’iednannia Prohres” is a Ukrainian structural steel manufacturer operating its own production facilities with a full-cycle metal fabrication and processing workflow. The company produces large-scale steel elements for industrial and civil construction projects, including load-bearing frames, assembly units, and structural components.

Due to the significant dimensions and weight of the products, production requires an open spray area allowing unrestricted crane handling of oversized structures. To ensure consistent coating quality and safe working conditions, the company required a local exhaust ventilation (LEV) system with controlled airflow and efficient capture of paint overspray.

Project Objectives

• Establish an open 4.5×4.5 m spray zone for oversized steel products.
• Install two water wash exhaust units with externally mounted fans.
• Provide uniform top-down air supply via a ceiling distribution frame.
• Integrate a full-area water-flooded floor system.
• Install a separate TVU with a 60 kW electric heating section.
• Ensure compliance with PUE requirements and Class V-IIa hazardous area standards.

Solution

A two-zone spray booth based on the FKG-4.0 model was installed and adapted to the customer’s facility layout. The working area is formed by a structural steel frame with ceiling-mounted supply air distribution. Total exhaust frontage width — 4600 mm. Working zone depth — 4500 mm. Working height — 3480 mm.

The exhaust units are mounted externally to reduce indoor noise levels and enhance fire safety. Exhaust air is discharged through ductwork (manufactured by the customer) with a minimum cross-sectional area of 0.16 m².

The supply thermo-ventilation unit (overall length 2770 mm) is equipped with an 11 kW fan motor and a 60 kW electric heating section. The heating system is divided into three stages to ensure phased electrical load distribution.

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Key System Components

• Water wash exhaust units — 2 units. Provide capture of paint overspray and water-based filtration of aerosol particles.
• Externally mounted exhaust fans — 2 units. Discharge filtered air outside the building, reducing indoor noise levels and minimizing ignition risk.
• Water-flooded floor system with grated collection tanks — 4 units. Collect paint residues, ensure liquid circulation, and prevent contamination buildup in the working area.
• Supply thermo-ventilation unit (TVU) — 1 unit. Delivers filtered and heated air to the working zone through a ceiling distribution system.
• Electric heating section — 1 unit. Maintains the painting temperature regime (≤23.5°C) with staged power control.
• Submersible pumps — 4 units. Ensure water circulation within the water wash and floor system.

Technical Specifications — FKG-4.0 Spray Booth

Operating Principle

Supply air is delivered from above through a ceiling air distribution frame, forming a uniform vertical airflow within the working area. A controlled air velocity of 0.15–0.25 m/s ensures stable coating application without turbulence or secondary contamination.

During spraying operations, paint overspray is directed by the airflow toward the front water wash exhaust units. At the water curtain face and spray zone, primary capture of paint particles occurs through water-based filtration.

Additional purification is provided by a fiberglass Paint Stop filter, after which the filtered air is discharged outside the building by the exhaust fans.

The integrated water-flooded floor system collects residual paint and ensures continuous liquid circulation via submersible pumps, maintaining stable water wash operation and minimizing contamination buildup within the working zone.

Maintenance and Safety

The system complies with GOST 12.2.003-74 and PUE regulations. Exhaust fans are installed outside the workshop to reduce ignition risk. All metallic structures are properly grounded.

The preventive maintenance schedule includes cleaning of water floor collection tanks, replacement of filtration media, and routine inspection of pumps and ventilation equipment.

Results

• Established a 4.5×4.5 m working zone for oversized steel structures.
• Stable and controlled vertical airflow.
• Efficient water wash capture of paint overspray.
• Reduced indoor noise due to external fan installation.
• Compliance with explosion and fire safety requirements.

Summary

The project for PrJSC “Ob’iednannia Prohres” delivered an industrial open-type water wash spray booth for processing large-scale steel structures. The system integrates water wash filtration, a full-area water floor, and a ceiling-mounted supply air system with electric heating, ensuring stable and safe operation of the painting department.

Request a Commercial Proposal

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

Start of Collaboration

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

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

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

Painting Complex for Locomotives

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

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

Thermo-Ventilation Group

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

Advantages

These solutions enabled:

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

Results

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

Conclusion

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

In 2018, representatives of the State Enterprise “Yuzhnoye Design Office named after M.K. Yangel” approached us with a request for a chamber for applying protective coatings to rocket bodies manufactured by the enterprise. Implementing such a project is a significant milestone in our company’s development and a great honor, so we made every effort to win this tender and supply equipment of the highest quality.

This chamber has internal dimensions of ten meters in length, four meters in width, and four meters in height, installed on a foundation base with underground air exhaust channels. The chamber cabin is a dead-end type, equipped with three-leaf swing gates with an opening of 3.6 x 3.6 meters. The cabin and thermoventilation cabinets are entirely white, as per the customer’s requirements.

The thermoventilation group consists of two supply ventilation cabinets and one dual exhaust cabinet with an activated carbon filter block. The thermoventilation cabinets utilize high-efficiency centrifugal ventilation units manufactured by Nicotra Gebhardt, Italy. Two ventilation units handle air supply, and two handle exhaust, each with a capacity of 25,000 m³/hour, ensuring a constant downward airflow in the chamber at a speed of at least 0.25 m/s.

The air in the chamber is heated using two powerful electric heat exchangers with thick-film metal-ceramic heaters of our own production. The heat exchangers feature a special design developed specifically for use in spray booths, accommodating a large airflow. This allows them to heat a substantial air volume — 25,000 m³/hour — to a delta of 40°C with relatively low energy consumption, ranging from 30 to 90 kW/hour. Additionally, smooth heating power regulation and precise temperature control ensure a minimal temperature variation in the chamber’s operation — ±5°C. Thanks to the powerful heat exchangers, the chamber easily maintains the required operating temperature regimes: coating application at 20°C with a temperature variation of ±4°C, and drying mode at 60°C with a temperature variation of ±5°C.

Exhausted air is purified before release using three types of filters: cardboard, fiberglass, and carbon. This ensures the highest level of purification from both contaminated particles and odors, meeting the strictest European environmental standards for painting facilities. From late 2018 to April 2020, there were no equipment failures, demonstrating its high reliability and receiving positive feedback from the operating staff.

This project is a source of pride for our company. We are honored to be a supplier for the State Enterprise “Yuzhnoye Design Office named after M.K. Yangel” and to contribute to the production of rocket and space technology. Collaboration with such an enterprise has been a significant achievement for us, and the quality of our equipment has been proven through real-world operation.

 

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About the State Enterprise “Yuzhnoye Design Office”

The State Enterprise “Yuzhnoye Design Office named after M.K. Yangel” is a leading Ukrainian enterprise located in Dnipro, Ukraine. Founded in 1954, it specializes in the development of rocket and space technology, including launch vehicles, spacecraft, and satellites. The enterprise plays a key role in Ukraine’s space industry and has extensive experience in international cooperation.

In 2018, TWEKO completed a project to modernize the painting section for Avtotehservis LLC, an auto repair shop in Kharkiv specializing in vehicle repair and restoration. The new painting and drying chamber with a diesel burner and refurbished equipment confirmed the company’s reliability and professionalism.

In 2018, our long-term partner, Avtotehservis LLC, approached us with the need to modernize the painting section of their auto repair shop. The company is based in Kharkiv and focuses on vehicle repair and maintenance. Due to the expansion of their service station, they decided to purchase an additional painting and drying chamber measuring 7000 × 4000 × 2700 mm with a diesel burner. Additionally, to improve logistics and optimize the use of workspace, they opted to relocate and refurbish an existing chamber purchased from TWEKO over 10 years ago.

Why Techservice VEKO?

Avtotehservis LLC carefully reviewed the available offers on the painting chamber market and chose us because we offer:

• Extensive experience.
• An in-house design department.
• Own manufacturing facilities.
• Use of reliable components.
• An in-house service department.

Our designers have many years of experience in the industry, allowing our company to guarantee the customer high-quality products even at the design stage. TWEKO painting chambers, when operated according to recommendations, have an exceptionally long service life.

Advantages

1. Custom equipment design tailored to the needs of the auto repair shop.
2. High painting quality thanks to a modern chamber with a diesel burner.
3. Reliability and durability of both new and refurbished equipment.
4. Prompt fulfillment of warranty obligations and attentive customer service.

Equipment and Work Performed

We have been collaborating with Avtotehservis LLC for over ten years, so the development of the new painting and drying chamber and the relocation with refurbishment of the existing one posed no challenges. After agreeing on all technical aspects, the equipment was manufactured, delivered to the site in Kharkiv, installed, commissioned, and staff training was conducted.

The new complex includes:

• A painting and drying chamber with a diesel burner, internal dimensions: 7000 × 4000 × 2700 mm — for painting and drying vehicles.

Additionally, TWEKO performed:

• Relocation and refurbishment of the existing painting and drying chamber, which has been in operation at the facility since the early 2000s.

The equipment manufacturing, installation, and commissioning were completed within the agreed timelines and in full compliance with the technical specifications. The equipment was installed at the auto repair shop in Kharkiv and is used for vehicle repair and painting.

TWEKO performed the work with high quality, adhering to deadlines and customer requirements. We also fully meet warranty obligations, providing prompt service support. The refurbished chamber continues to operate reliably, confirming the durability of our technical solutions.

Avtotehservis LLC is fully satisfied with the results and recommends our company as a reliable partner. We, in turn, are proud of this collaboration and are ready to help other businesses in the auto repair industry elevate their painting processes to a new level.

Conclusion and Results

The project, implemented in 2018 for Avtotehservis LLC, is an example of successful modernization of an auto repair business. Thanks to years of collaboration, we deeply understood the client’s needs, so the development of the new painting and drying chamber and the refurbishment of the existing one were carried out smoothly and efficiently.

After agreeing on all technical aspects, we manufactured and delivered the equipment, performed installation, commissioning, and staff training. The new equipment ensures high-quality painting and meets modern industry standards.

The project was implemented under Contract No. 20 dated June 22, 2018 between TOV «Tekhservis VEKO i partner GmbH» and TOV «NVO Vertikal». The paint and drying booth was commissioned in November 2018 in Kharkiv, enabling the client to significantly increase productivity and improve the quality of large-sized structure processing.

The beginning of cooperation

TOV «NVO Vertikal» is a Kharkiv-based scientific and production association founded in 2000 and specializing in electrical equipment. The company develops, manufactures, supplies, and services power equipment, electric drives, control systems, telemetry systems, and reactive power compensators. «NVO Vertikal» invests in employee development, creating conditions for professional growth and ensuring consistent product quality.

In 2018, under Contract No. 20 dated June 22, 2018, TWEKO implemented a project for the supply and installation of a paint and drying booth for TOV «NVO Vertikal». The cooperation between TWEKO and «NVO Vertikal» was focused on optimizing the production process for large-sized metal structures in Kharkiv.

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Design features

The mobile paint and drying booth of the MKFS series from TWEKO, designated “Vertikal”, was designed for painting complex large-sized metal structures. It ensures high coating quality and reduces processing time. The main design characteristics are:

• Compact footprint and expandable working area: In the folded state, the booth has a length of 1850 mm, and when unfolded, it provides a working area of more than 15 × 5 × 5 m for handling large products (according to TWEKO).
• Stationary base: The supply and exhaust air handling unit (AHU) is installed on a foundation base, ensuring operational stability and efficiency.
• Protective material: Fire-resistant silicone-coated fabric is used, capable of withstanding high temperatures and mechanical loads.

According to TWEKO, this design reduced painting time from 2–3 days (with natural drying) to approximately 8 hours (one night shift), confirming the efficiency of the equipment for painting metal structures.

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Booth operating principle

The project included two operating modes — «Painting» and «Drying», requiring precise ventilation control and process automation.

Operating modes

• Painting mode: Air is supplied through the air handling unit (AHU), filtered to remove dust, heated in a heat exchanger, and delivered through a ceiling fine filter into the booth. Contaminated air with paint particles passes through the floor filter and is discharged outside via the exhaust system. Stable pressure is maintained to ensure air quality inside the booth.
• Drying mode: The booth operates in recirculation mode with fresh air intake. The process is automated: the operator sets the temperature and drying time. The cycle includes a purge phase (post-paint ventilation) and a drying phase (recirculation of heated air through the heat exchanger and filters). The timer starts only after the set temperature is reached.

Client feedback

TOV «NVO Vertikal» highly appreciated the quality of TWEKO’s work, confirming that the booth meets the declared specifications:

Conclusion

The 2018 project for TOV «NVO Vertikal» demonstrated TWEKO’s capability to deliver paint and drying booths for large-sized structures. The MKFS series booth became an important element in optimizing production, reducing painting time, and improving coating quality.

Demonstration of the booth in operation: