A highly productive and technologically advanced paint shop for different vehicle sizes
The plant is located within a new repair and painting centre for vehicles of different sizes, from cars to vans to trucks.
As an authorised centre for a well-known car manufacturer, it has to meet high quality standards, both in terms of the level of finish of the work and the speed of execution of the job.
Request
They required a paint shop with a layout designed to optimise flows within the bodyshop, improving productivity during all processing stages, from preparation to painting.
The use of the most advanced and innovative repair and painting technologies was necessary to offer customers high quality finishes with reduced running costs.
Solution
We designed a painting plant with a layout that minimises movement, eliminating downtime between processes.
The plant consists of a dedicated area for preparing vehicles for painting, comprising two double Genius preparation zones for cars, a dedicated preparation zone for medium-sized vehicles (vans) and an extra large Genius preparation zone for trucks and buses. The zones are equipped with an efficient underfloor extraction system, under-wheel lifts integrated in the grid, IR/UV spot repair drying lamps and motorised curtains.
The painting area includes a standard-sized Extra spray booth and a larger booth for painting vans. This is complemented by a mixing box for safe paint preparation. The management of all processes takes place via a touchscreen PLC, for precise and fast smart control of all painting parameters, optimising energy consumption.
In a separate area there is a preparation zone dedicated to working on aluminium and polishing.
Ventilation is managed by high-efficiency thermo-ventilating units, with an air vein burner, equipped with inverter and heat recovery, for a reduction in electricity consumption of up to 30% and a reduction in fuel consumption of up to 50%. This results in significant savings in painting plant running costs and improved environmental sustainability.
