A successful industrial coating line is planned by evaluating product flow, process stages, capacity and factory layout as one complete system—not simply by selecting a booth, oven or conveyor. Choosing equipment before the products, coating system, production targets and existing plant conditions are clearly defined can lead to bottlenecks, energy losses and costly modifications.

For an accurate technical quotation, product dimensions and weights, material and surface condition, hourly and annual capacity, paint and chemical data, quality targets and available utilities should be defined with measurable information wherever possible. These inputs allow the pre-treatment, application, handling, drying, curing, ventilation and automation systems to be sized for the actual production requirement.

This guide explains the technical data, capacity calculations and principal planning steps to prepare before requesting a quotation for liquid paint, powder coating, e-coat (KTL) and similar industrial coating lines. At Elsisan, we evaluate these inputs not only against target capacity, but also in relation to energy consumption, operating cost, process reliability and future growth.

1. Define the Products to Be Coated

Average product dimensions alone are not sufficient when planning a coating line. The complete product family must be evaluated together, with separate attention given to the largest, heaviest, highest-volume and most difficult-to-coat or handle products. This establishes the correct design limits and allows the equipment to be sized for the actual production requirement.

1.1. Minimum and Maximum Product Dimensions

Product width, length and height directly affect the sizing of the pre-treatment system, coating booth, oven, conveyor route and automatic application zones.

Accurate maximum dimensions are particularly important for defining booth and oven openings, safe spacing between products, conveyor curves and required line clearances. If a product may swing or rotate during transport, this movement must also be included in the design envelope.

1.2. Product Weight and Material

Product weight is a primary input for determining conveyor capacity and hanger or fixture design. On suspended lines, the combined load of the product, hanger, fixture and carrier must be considered. Weight data is also essential for planning safe and ergonomic loading and unloading. Where heavy parts are unsuitable for manual handling, suitable lifting and transfer equipment should be evaluated during the project stage. Correct planning reduces operator workload, improves loading and unloading times and supports stable operation at the target capacity.

Product material is an important factor in defining the pre-treatment and coating process. Steel, aluminium, galvanised steel and other materials can require different cleaning, pre-treatment, drying and coating stages. The material and existing surface condition should therefore be clearly identified at the start of the project.

1.3. Surfaces to Be Coated

The existing surface condition is as important as the substrate material. Oil, corrosion, manufacturing residue or any previous coating should be clearly identified and evaluated when defining the pre-treatment and coating process.

Technical drawings should clearly indicate the areas to be coated, left uncoated, protected or masked. Threaded holes, electrical contact points, assembly surfaces and similar details directly affect gun positioning, application access and masking requirements.

1.4. Hanging Method

When defining the hanging method, consider the product orientation and direction of travel, suspension points, number of parts per hanger and any need for rotation. The product must remain stable and secure; its centre of gravity, risk of swinging and clearance through booths, ovens and other openings must be reflected in the fixture design.

Marks that may be left by hangers and contact points, and whether those points will remain visible on the finished product, should be evaluated in advance. Where electrical contact is required, its location should be clearly defined in the drawings and hanger design.

If chemical pre-treatment is used, product orientation requires additional consideration. Where the part contains pockets that could retain water or process chemicals, it should be suspended in an orientation that allows liquids to drain freely.

1.5. Preparing a Product Matrix

Instead of evaluating products independently, prepare a product matrix that presents the principal technical data for all product groups together.

The values below are examples only.

Product Group	Dimensions	Weight	Material	Units per Hour
Product A	500 × 400 × 300 mm	12 kg	Steel	80
Product B	1.200 × 600 × 400 mm	35 kg	Galvanised Steel	25
Product C	800 × 500 × 250 mm	8 kg	Aluminium	45

The product matrix is used not only to show product diversity, but also to establish the actual design limits of the coating line. Evaluating dimensions, weights, materials and production quantities together makes it easier to determine which product groups should govern the line sizing.

Products with low production volumes but unusually large dimensions or weights should be evaluated separately. Including these parts on the main line can significantly increase booth and oven dimensions, conveyor capacity, line length, energy demand, floor-space requirement and total investment cost.

For example, a plant producing mainly 600 × 400 mm parts may also need to coat a limited number of 3,000 mm products. Sizing the entire system around this exceptional part can create additional capacity with a very low utilisation rate. In such a case, evaluate whether coating that product by a different method outside the main line would be more appropriate technically and economically.

A product matrix helps clarify the following decisions:

• Which product or product group should govern the line dimensions.
• Whether low-volume or exceptional parts can be handled outside the main system.
• Which products have the greatest impact on the investment budget.
• Whether separating the main production line from special-product solutions is technically and economically appropriate.

The objective is not to include every product in the same system, but to define the correct project scope by considering product dimensions, production volumes, technical requirements and investment economics together. This makes it possible to engineer a line that matches the actual production need instead of an oversized system with substantial unused capacity.

At Elsisan, we evaluate product diversity and production targets together from the start of the project to establish a balanced scope in terms of investment cost, energy consumption and operating efficiency.

2. Determine Production Capacity

Coating-line capacity should not be determined from annual production volume alone. Hourly and daily targets, shift pattern, product and colour-change frequency, the share of each product group and planned future capacity increases should be evaluated together.

For conveyorised coating lines, theoretical capacity can be calculated as follows:

Theoretical Capacity Calculator

Conveyor speed m/min

− +

Hanger pitch m

− +

Products per hanger units

− +

Shifts

1 2 3

Calculation period

Hourly Daily Monthly Annual

Daily theoretical capacity 480 products/day

8 hours/shift · 22 days/month · 12 months/year

The result is theoretical; actual capacity varies with process times, stoppages and product changes.

This value alone does not represent the line’s actual production capacity. Loading and unloading times, operator count, product and colour changes, cleaning, manual touch-up, process waiting times, oven residence time and planned stoppages must also be considered when determining net capacity.

Actual line capacity therefore depends not only on conveyor speed, but on whether all process stages can operate at a compatible production rhythm. Insufficient capacity or a cycle-time mismatch at any stage can create a bottleneck and reduce output below the theoretical capacity.

3. Evaluate Factory Layout and Utilities

Correct placement of the coating line within the factory is as important as selecting the right equipment. A scaled factory layout should therefore be provided before quotation wherever possible.

The layout should clearly show available floor area, ceiling height, columns, doors, access routes, existing machinery and product entry and exit paths. Product flow should be compatible with the existing production arrangement to reduce unnecessary handling distances and internal traffic.

Available electrical power, natural gas, compressed air, process water, wastewater and exhaust connections should also be shared at the start of the project. These inputs support both equipment positioning and the planning of auxiliary systems and connection points.

Layout planning should not focus solely on fitting equipment into the available space. Sufficient access must be retained for safe maintenance and servicing of filters, fans, motors, burners, pumps, conveyors and electrical panels.

If future capacity increases, new products or additional equipment are anticipated, these growth scenarios should also be considered during quotation and engineering.

3.1. Future Capacity Increase and Modular Design

A coating line should be designed around both current production targets and the company’s expected growth. This does not mean oversizing the line during the initial investment.

Correct planning creates a flexible infrastructure that can accommodate an additional booth, more spray guns, conveyor extensions, increased shifts or expansion of selected process sections when required.

At Elsisan, we engineer our lines with a modular design approach that considers future changes and growth. Our in-house panel systems use structures that can be dismantled and reassembled on site instead of welded, permanent joints.

This allows the existing system to adapt to different configurations without complete replacement when capacity increases, product dimensions change or the plant layout must be reorganised. Booths or process sections can be extended, the layout can be revised and existing structures can be repositioned with new equipment in a more controlled manner.

To plan this flexibility correctly, share not only current production volume but also, where possible, the expected growth over the next three to five years, planned new products and potential capacity-increase scenarios. The required infrastructure for later expansion and layout changes can then be anticipated from the start.

4. Select the Coating Application Method

4.1. Manual, Automatic, Robotic and Hybrid Coating Applications

The application method should be selected by considering not only production volume, but also product geometry, part diversity, colour-change frequency, difficult-to-reach surfaces, quality targets and the need for operator intervention.

Manual application can suit projects with high product variety, limited volumes or frequently changing geometries. The operator’s ability to adjust position and technique to the part provides valuable flexibility in low-volume and variable production.

Where products with similar geometries move at a regular production rhythm, automatic spray guns may be used. In automatic applications, the guns can be controlled using vertical gun movers (reciprocators), horizontal in/out positioners, or multi-axis motion systems configured for the product geometry. Product position on the conveyor, spacing, product height, conveyor speed, number of guns and target film thickness directly affect the automation design.

Robotic coating may be considered where complex geometries must be reached repeatably, coating recipes for different products must be stored and high process repeatability is required. Robot selection alone is not sufficient: reach envelope, booth dimensions, paint supply, part handling and positioning, safety equipment and control architecture must be engineered as an integrated system.

Automatic application should not be expected to cover every geometry and surface without support. Manual touch-up may be needed for deep recesses, internal corners, reverse surfaces, weld zones or areas affected by the Faraday cage effect during electrostatic application.

For this reason, many plants use hybrid coating systems rather than exclusively manual or automatic application. Automatic guns coat broad, accessible surfaces while an operator completes complex or difficult areas. This combines the speed, repeatability and transfer efficiency of automation with the geometric flexibility of manual application.

At Elsisan, we develop the application architecture around product geometry, production speed, colour-change frequency and target coating quality. Where required, we plan hybrid systems supported by manual touch-up, gun-moving systems adaptable to different product groups and infrastructure that can accommodate future automation.

5. Define the Process Flow

Once the product characteristics, production capacity and application method have been defined, the process flow can be established.

A typical industrial coating line may include the following stages:

1. 01 Loading Placing the product on its hanger or carrier
2. 02 Pre-treatment Mechanical, chemical or external process
3. 03 Coating Application Single- or multi-coat application
4. 04 Flash-off According to solvent and process requirements
5. 05 Drying / Curing Final or intermediate curing
6. 06 Cooling After a heated process
7. 07 Unloading Removing the product from its hanger or carrier

Note: This is an example process sequence. Depending on the coating system and layer structure, pre-treatment may be performed outside the line; coating application, flash-off and intermediate curing stages may be repeated, or some stages may be omitted.

The process sequence may vary according to the coating type and product characteristics.

Where mechanical surface preparation is sufficient, a chemical pre-treatment line may not be required. In liquid-paint systems one or more flash-off zones may be positioned between primer and topcoat applications, or separate booths may be used for different layers. In standard powder-coating applications, the product is generally transferred directly to the curing oven after application, so a separate flash-off process is normally unnecessary.

The process flow should therefore not be copied from a standard template. It must be developed for the project according to the product’s surface condition, coating type and application method, production capacity and quality targets.

6. Select the Right Material Handling System

The material-handling system moves products between pre-treatment, coating, drying, curing and other processes. Its selection therefore directly affects line capacity, layout and process continuity.

The handling system should not be selected from product weight alone. Product dimensions, hanger pitch, line speed, curve radii, elevation changes, loading and unloading times, inter-process accumulation requirements and product positioning must be evaluated together.

Depending on the project and process structure, the following solutions may be considered:

Handling Systems	Handling Principle	Typical Applications
Overhead Systems	Products travel on hangers or carriers connected to an overhead conveyor track.	General industrial lines where clear floor space is preferred
Floor-Mounted Systems	Products travel on a floor chain, spindle or skid.	Wheels, plastic parts, automotive components and large or heavy products
Power-and-Free / Accumulation Systems	Carriers can be stopped, accumulated, separated and moved at different speeds.	Lines requiring different process times, buffers or product routing
Dip-Type Handling Systems	Products are immersed in process tanks and transferred to the next station.	Chemical pre-treatment, dip coating and KTL/e-coat processes
Manual / Semi-Automatic Handling	Products are moved between stations by operators or simple mechanical equipment.	Low-capacity, batch-type or high-mix plants
Special Handling Systems	Project-specific transfer solutions are developed.	Special products and processes not suited to standard handling systems

No single handling system is suitable for every coating-line project. The correct solution depends on product characteristics, process structure, production rhythm and future operating scenarios. Proper planning helps balance process times, organise loading and unloading and maintain continuous operation at the target capacity.

7. Main Sections of an Industrial Coating Line

The equipment used in a complete industrial coating line is determined by the product characteristics, production capacity and selected process. Depending on the project scope, the following main systems may be evaluated together.

7.1. Pre-treatment System

Spray pre-treatment lines, dip tanks, enclosed chamber systems, parts washers or mechanical preparation solutions may be used to prepare products for coating. The method is selected according to product material, existing surface condition, required cleanliness and coating-system requirements.

Related content: Pre-treatment Systems

7.2. Coating Booth and Application Equipment

The coating booth is selected according to product dimensions, coating type, application method, production capacity and available workspace. Depending on the project, liquid-paint or powder-coating booths for manual, automatic or robotic application may be integrated with spray guns, reciprocators, robots, paint-supply units, recovery systems and manual touch-up stations.

Related content:

• Powder Coating Systems
• Manual Powder Coating Booths
• Automatic Robotic Powder Coating Booths

7.3. Drying and Curing Ovens

Water-drying, liquid-paint drying or powder-curing ovens may be used according to the project. Infrared (IR) or ultraviolet (UV) technologies may also be considered where appropriate. Oven selection should be based on product dimensions and weight, hourly load, coating specification, target product temperature, process time, conveyor speed, available space and energy infrastructure.

Related content:

• Drying and Curing Ovens

7.4. Ventilation and Air-Conditioning Systems

Ventilation and air-conditioning systems are engineered to maintain the required air quality, temperature and humidity in the booth and related process areas. Supply and exhaust airflow, filtration stages, booth pressure balance, temperature and relative humidity are determined according to the coating type, product characteristics, process requirements and factory environment.

Heating, cooling, dehumidification or humidification may be integrated as required. Correct air conditioning helps maintain coating quality, reduce surface defects and improve process repeatability.

7.5. Energy Efficiency and Heat Recovery

Energy efficiency depends not only on equipment selection, but also on how heat and conditioned process air are managed between processes. Ovens, drying sections, coating booths and air-conditioning systems should therefore be considered together in terms of energy flow.

Depending on the project, hot air from ovens, heat in exhaust air or conditioned process air may be recovered at different points. Where suitable, this energy can preheat fresh air, support another process or reduce total demand. The objective is not merely to choose lower-consumption equipment, but to build a more efficient process by evaluating where energy is generated, used and discharged throughout the plant.

7.6. Automation System

A PLC- and HMI-based automation system enables line equipment to operate under a common process scenario, allows critical parameters to be monitored and provides centralised control. Depending on the project, RFID, barcode or similar identification can track products along the line and automatically call product-specific process recipes. SCADA systems can monitor, record and report process data.

At Elsisan, we engineer the automation architecture around the plant’s control, traceability and efficiency requirements, developing project-specific solutions that integrate mechanical equipment and control systems.

8. Pre-Quotation Information Table

To prepare a technical quotation around actual production conditions, provide the following information using current, measurable data wherever possible.

Information to Prepare	Details Required for Quotation
Product Data	Technical drawings, minimum and maximum dimensions and part weight for each product family.
Material and Surface	Material such as steel, aluminium or plastic, plus whether the surface is oily, corroded or pre-treated.
Coating and Masking	Marked drawings showing surfaces to be coated and areas to be protected, contacted or masked.
Capacity and Growth	Hourly, daily and annual targets, shift pattern and expected capacity increase.
Coatings and Chemicals	Powder or liquid coatings and process chemicals, with current technical and safety data sheets where available.
Colour Management	Number of active colours, batch size and daily or weekly colour-change frequency.
Quality Targets	Film thickness, appearance, adhesion, corrosion resistance and acceptance criteria.
Space and Layout	Available net area, ceiling height, column and door positions and preferred product flow.
Utilities	Available capacities and connection points for electricity, gas, water, compressed air and exhaust.
Automation and Traceability	Requirements for recipe management, data logging, alarms, reporting and ERP/MES integration.
Environment and Safety	Applicable environmental conditions, fire scenario, ATEX requirements and worker-exposure conditions.

8.1. Start the Quotation Process with the Right Data

Share the information already available; missing technical inputs can be clarified together during a preliminary review with the Elsisan engineering team.

Contact us about your project and start the quotation process.

Engineering Principles and Industrial Applications of different spray booth designs

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Introduction

Enclosed spray booths are engineered painting environments designed to provide controlled airflow, contamination prevention, and consistent coating quality. By managing air movement, filtration, and extraction systems, these booths ensure efficient overspray removal while protecting both the operator and the surrounding environment.

The selection of booth configuration depends on required finish quality, production volume, available space, and investment level. The three most common airflow configurations are Cross Draft, Side-Downdraft, and Full Down (Downdraft) systems. This article focuses on dry filter spray booth systems. For a detailed overview of filtration types used in spray booths, see our dedicated article: Filtration Types in Spray Booths.

1) Spray Booth Types

Let’s examine different spray booth types and have a quick overview of different models.

A) Cross Draft Spray Booths

Air Flow Principle

Advantages

• Lower investment cost compared to other models
• No pit requirement like the downdraft floor pits

Recommended Applications Areas

• Suitable for parts that are painted from one direction.
• Industrial equipment
• Medium-quality coating processes

B) Side DownDraft System

Airflow Principle

Advantages

• No need for a full floor pit system
• Lower installation cost than full downdraft
• Suitable for large and heavy objects

Recommended Application Areas

Customers who don’t prefer pit construction work and cannot have construction in their factory floors for a downdraft airflow. Suitable for large and heavy products that may require strong flooring.

• Industrial manufacturing plants
• Large metal structures
• Truck and bus painting

C) Full Down (Downdraft) System

Airflow Principle

Advantages

• High coating quality
• Excellent airflow uniformity
• High overspray removal efficiency

Recommended Applications Areas

Customers that can built pit construction or can have their spray booths elevated from the ground to accomodate the floor suction.

• Automotive OEM production
• Aerospace components
• High-gloss industrial finishing
• Class A surface coating processes

2) Part Handling Systems in Spray Booths

A. Overhead Carrying System Constructed Inside the Booth

Working Principle

Parts are attached to hooks or fixtures and conveyed via a motor-driven rail system installed above the working area. This keeps the floor area clear and allows continuous production flow.

Advantages

• No additional openings in the booth structure required, preserving the integrity of the controlled environment
• Compatible with ATEX-certified explosion-proof configurations for solvent-based coating environments
• Enables continuous production flow with minimal manual intervention
• Parts can be rotated during conveying to allow coating from multiple angles without stopping the line

B. External Overhead Bridge Crane System

Working Principle

Workpieces are lifted by an external bridge crane using hooks, chains, or spreader beams. The crane travels along rails positioned above the booth and lowers the part directly into the booth through large access doors or an open-top design. After coating, the crane lifts the part out and transports it to the next production stage. A single crane can serve multiple booths or work areas, improving overall production flexibility.

Advantages

• Handles very large and extremely heavy workpieces
• No internal conveyor installation required inside the booth
• One crane can serve multiple booths or production areas
• Lower booth investment compared to fully integrated conveyor systems
• Flexible for varying part sizes and geometries

C. Floor Ground Rail System

Working Principle

Workpieces are placed on wheeled trolleys that travel along floor-mounted rails. This system is particularly suitable for large and heavy components.

Advantages

• High load carrying capacity
• Suitable for heavy-duty applications
• Stable and secure transport
• Easier maintenance access

D. Manual Wheeled Cart System

The Manual Wheeled Cart System is the simplest and most cost-effective part handling method. Workpieces are loaded onto wheeled carts or platforms and manually pushed into the spray booth by operators. This approach requires no powered drive systems or fixed infrastructure, making it easy to implement in any booth configuration.

Working Principle

Parts are loaded onto wheeled carts or dollies at a preparation area outside the booth. Operators manually push the loaded carts through the booth doors and position them for coating. Once the painting process is complete, the carts are rolled out to a drying or curing area. No electrical connections or fixed guide tracks are required.

Advantages

• Lowest investment and installation cost
• Minimal maintenance requirements
• Maximum flexibility for different part types and sizes
• No special floor infrastructure or electrical systems required
• Easy to reconfigure or expand production layouts

3) Spray Booth Door Types

The door system of an enclosed spray booth determines how parts enter and exit the coating area. The right door type depends on part size, production flow, and available floor space.

A) Manual Hinged Front Doors

B) Automatic Motorized Bi-Fold Doors

C) Roller Doors

• Maximizes clear opening width and height
• No floor space consumed by door swing
• Suitable for large workpieces and vehicle-sized parts

4) Positive and Negative Pressure Booths

A) Positive Pressure Booths

This design delivers a cleaner, more controlled coating environment, making it the preferred choice for applications with high finish quality requirements. The trade-off is a higher initial investment, as the system requires both supply and exhaust fan assemblies along with more sophisticated air balancing controls.

B) Negative Pressure Booths

While this configuration is simpler and less costly to install, it is more sensitive to the condition and integrity of the booth enclosure. It remains a practical and widely used solution for coating operations where the highest level of cleanliness is not the primary requirement.

5) Air Handling Units (AHU) in Enclosed Spray Booths

Air Handling Units (AHUs) are responsible for depending on the customer requirements they can be equipped to control air quality, temperature and humidity inside the spray booths. Their main purpose is to ensure stable coating conditions, consistent drying performance, and optimal working environment. AHU units are located before the intake air and are categorized under the pressurized spray booth types. (Which means rather than having a simple intake fan, these handling units can refine the air in more advance requirements for customer requirements)

A) Heating Systems

• Heating outside air
• Maintain constant spraying temperature
• Accelerate paint drying and curing process
• Ensure stable operation during cold weather

How It Works

Fresh outside air is drawn in, warmed as it passes through the heating unit, and then supplied into the spray booth through the intake filters.

Spray booth heating systems generally operate using one of the following methods:

a1) Direct Gas Burner System

• Natural gas or LPG is burned directly in the airflow path
• The heated air is supplied directly into the booth
• High thermal efficiency

a2) Indirect Gas Heating System

• Combustion occurs in a separate chamber
• Heat is transferred through a heat exchanger
• Exhaust gases do not mix with process air
• Provides cleaner airflow into the booth

b) Electric Heating System

c) Hot Water and Steam Heat Exchanger Systems

Hot water and steam heat exchanger systems heat the incoming air indirectly by passing it over a coil or heat exchanger that carries hot water or steam from a central boiler or district heating network. The combustion or heat generation happens remotely, and only the heated medium is circulated to the spray booth unit.

• Clean and safe heating with no combustion inside or near the booth
• Well suited for facilities that already operate a central boiler system
• Consistent and stable heat output

B) Cooling Systems

The purpose of the cooling systems is to prevent overheating during summer conditions or in hot climates, to maintain stable temperature to stabilize paint viscosity, and to improve operator comfort. Cooling is typically achieved through chilled water coils or direct expansion (DX) refrigeration units integrated into the AHU assembly.

• Prevents overheating in high-ambient-temperature environments
• Maintains stable paint viscosity for consistent application results
• Improves operator working conditions during summer operation

C) Humidification Systems

Humidity control in a spray booth affects finish quality, paint behavior, and dust management. Both extremes are problematic: air that is too dry causes static buildup, dust attraction, and dry spray as paint skins too quickly; air that is too humid slows solvent evaporation, increases the risk of sags and runs, and can trap moisture beneath clear coats. Waterborne paints are particularly sensitive to humidity, as high relative humidity (RH) significantly delays flash-off and can cause mottling and extended cycle times.

• Reduces static electricity buildup and airborne dust attraction on freshly coated surfaces
• Prevents dry spray and poor leveling caused by excessively dry air
• Critical for waterborne paint lines where tight RH control is often required by paint supplier or OEM specifications
• Eliminates seasonal coating quality variation, particularly during winter heating cycles when indoor humidity drops significantly

6) Automation and Control Systems in Enclosed Spray Booths

Automation and control systems in enclosed spray booths are designed to ensure process stability, safety, energy efficiency, and consistent coating quality. These systems integrate mechanical components, sensors, and programmable logic controllers (PLC) to maintain precise environmental and operational conditions. Advances systems can include Scada and additional features on customer requests. Here is a quick overview of the features.

Core Automation Components

PLC (Programmable Logic Controller)

The PLC serves as the central control unit. It monitors system inputs and controls outputs such as fans, burners, dampers, and heating elements according to programmed logic.

Sensors

• Temperature sensors
• Humidity sensors
• Pressure sensors
• Airflow switches
• Gas detection sensors (Upon request)

These provide real-time data for closed-loop control.

Airflow and Pressure Control

Automation systems regulate:

• Supply fan speed (via VFD – Variable Frequency Drive)
• Exhaust fan speed
• Damper positions

This ensures:

• Balanced airflow
• Controlled positive pressure inside the booth
• Prevention of dust infiltration

Pressure Sensors and Automatic Filter Replacement Alert Feature

Differential pressure sensors are used to continuously monitor filter loading. As a dry filter accumulates overspray and particles, the pressure drop across the filter increases. When the pressure difference reaches a set threshold, the system triggers an alarm to notify the operator that the filter needs to be replaced. This prevents degraded airflow, inconsistent booth pressure, and reduced capture efficiency, all of which directly affect finish quality.

Operational Modes

Automation enables different predefined modes:

Spraying Mode

• Lower temperature
• Balanced airflow
• High filtration efficiency

Curing Mode

Curing mode is only available on booths equipped with a heating unit.

• High temperature
• Recirculated airflow
• Reduced fresh air intake for energy efficiency

Energy Efficiency Features

Modern automation systems include:

• Variable Frequency Drives (VFD)
• Air recirculation control
• Proportional burner control
• Heat recovery systems (Can be added upon request)

These reduce operational energy costs while maintaining performance.

7) Conclusion

Enclosed spray booths are engineered systems designed to ensure controlled airflow, stable environmental conditions, and consistent coating quality across industrial applications. The selection of appropriate airflow configuration — Cross Draft, Side Downdraft, or Full Downdraft — directly influences finish performance, contamination control, and operational efficiency.

When supported by integrated part handling systems, advanced Air Handling Units (AHU), and PLC-based automation, enclosed spray booths provide precise temperature, pressure, and humidity management throughout all operational modes. This integrated approach enhances product quality, improves workplace safety, and optimizes energy consumption.

In modern industrial environments, enclosed spray booths function not only as painting enclosures but as fully controlled process systems that deliver reliability, repeatability, and long-term production efficiency.

Industrial Glass Painting Technologies

 In the glass industry, which is gaining momentum today, serial painting of bottles and glasses is done by fully automatic machines. Products such as glass bottles, glasses, souvenirs, glassware are painted with two types of paint, organic and inorganic. Organic paints are water-based or solvent-based double components. Paint application; can be made by air injection, roll printing and silk screen print methods. Organic paints can be dry by air drying, oven drying and UV drying. After drying, the paint forms a hard film.

Inorganic paints are water-based or solvent-based, single component. Matte coating process can also be applied as frosting. The glass is mattified with the matting frosting application and a frosted appearance is provided on the surface. Paint application; can be made by air spray, roll printing and silk screen print methods. Inorganic paints are dried at ovening temperatures starting from 550°C. The paint becomes a complete whole with the glass after ovening process.
 

Air Spray Paint Application

Glass products to be painted are loaded from the loading area to the conveyor flowing at the adjusted speed by the operator or the robot. The glass first goes through the flaming process to abrade its surface. In the flaming process, the glass surface is exposed to thermal oxidation for less than one second with the flame formed by using gases such as methane, propane, butane. With the flaming process, the ability of the paint to adhere to the surface is increased. In the continuation of the coating process, the product passes in front of the antistatic cleaning unit in order to remove the static tension on the surface. The surface is statically cleaned and ready for paint.

Painting can be done with a conventional air gun, bell gun or disc system in accordance with the capacity and the shape of the glass piece. With conventional air guns, many different colors can be applied at the same time in cases where quality expectations are not high.

Thus, the inventory cost is reduced and the packaging time is shortened. In mass productions with high capacity, thanks to the 80-90% transfer efficiency with the Bell gun and disc system, despite the increase in paint prices, economy in paint consumption is ensured. Bell and Disk systems provide excellent paint uniformity and quality. Extremely low overspray reduces cabin exhaust flow and reduces cleaning requirements.

Cabin where paint applications are made; It can be produced in two different types with water screen or dry filter. Today, dry filter technology has progressed positively and has become more preferred.
 

Paint application is made in a positive pressure room. With the help of positive pressure booth, the paint application is isolated from the external environment and dust entry into the cabin is prevented. In all painting systems, the glass is rotated around its axis during painting. Paint-applied products enter the flash-off section. Resting before the oven is done by staying in the flashoff for about 10 minutes.

Paint drying oven can be made with conventional or infrared. In infrared ovens, the oven time is shortened by 1/3. For example, the curing time, which is 20-25 minutes in conventional conventional ovens, decreases to 6-8 minutes. Fans are used for heat distribution in conventional furnaces. With the fan circulation, dust flying in the fan also occurs. Since there is no air circulation in the infrared oven, the paint is cured in a dust-free environment.

Glass products coming out of the oven enter the cooling section and cool down to the touch temperature. Glass products after the cooling section; arrives at the unloading station. It is emptied and packaged by the operator or the robot or transferred to the high temperature furnace.
 

Glass Painting Technologies In Industry 4.0

Glass painting machines are machines suitable for the new industrial revolution defined as Digital Industry, 4th Industrial Revolution or Industry 4.0, with loading and unloading done by robots.

Conveyor and loading and unloading robots communicate and move synchronously through sensors communicating with each other in the glass painting machine. All of the glass painting machines are PLC and computer controlled. A separate recipe can be created for each product. Important values such as how many glass products are painted per hour, paint consumption, energy consumption, thermal energy consumption, stopping and working times can be recorded and reported. In addition, the user is warned with fault alarms and maintenance alarms depending on the anticipated maintenance period.
 

With the help of remote access, PLC system can be intervened and data can be received from the office or from a different country. Fully automatic glass painting machines can work completely unmanned with its developing technology, thus providing speed, economy, efficiency and quality. With the increase in efficiency and quality, the global market share of glass products can be increased significantly.

To get an detailed information about industrial glass painting, please visit product page from the link below

https://elsisan.com/tr/endustriler/cam-sektoru

Canay IŞIKMAN

Project Engineer

Project Department

Elsisan A.Ş