When an unexpected fire hit the paint rooms at Konesko's Koeru factory, a major challenge was faced. The production process was severely disrupted and the situation required a quick and efficient solution. Our task was to help the customer to overcome the crisis and to create completely new painting and drying rooms that meet today's requirements and ensure safe and efficient production.
The main objective of the project was to create two functional colour spaces - one for large and heavy products and one for smaller and lighter ones. In addition, the rooms had to be equipped with drying facilities and ensure efficient ventilation, lighting and remote control of equipment. All the equipment had to comply with the requirements for Ex-proofing and the work had to be carried out without interrupting daily production.
How did it all happen?
The work was carried out in two phases. First, we built a painting and drying room for larger products. This room was equipped with a powerful 15,000 m³/h Ex-rated ventilation system, which ensures a constant supply of fresh air and efficient air exchange. For future needs, we also added the possibility to easily integrate a cooling function. The equipment in the room was mounted on a special fire-resistant metal structure, separated from the rest of the production area by fire-resistant walls. All the solutions complied with the requirements for Ex-proofing.
For the processing of larger products, Konesko has added an Ex-ready shelf to the colour room, making it easy and convenient to lift and move products. The drying room has been equipped with an Ex-equipped drying solution, which automatically regulates the fresh air flow by means of solvent sensors, ensuring both operational safety and optimal energy efficiency. Proper Ex-lighting was installed in all rooms to ensure optimum working conditions and to allow for high quality production.
In the second phase, we focused on the creation of a colour room for smaller products with an effective air exchange rate of 10000 m³/h and a drying tunnel. In the smaller colour room, we used modern energy-saving solutions, complying with all possible standards and safety requirements that colour rooms need to meet. In addition, the "Power&Free" conveyor system allowed for a fast movement of the products, while ensuring sufficient drying time, as the products in the drying tunnel are not in continuous movement.
The result: innovation and efficiency!
The resulting solution is not just a solution to a problem - it is an example of how a crisis can be an opportunity for innovation. Modern Ex-proof ventilation, lighting and automation solutions ensure energy efficiency, safety and ease of use. Thanks to solvent sensors and compressed air readers, the system optimises ventilation as needed, saving resources when no active painting is taking place.
This project is proof of how, with smart and thoughtful action, it is possible not only to rebuild but also to improve in difficult circumstances. We are proud to have been able to help Konesko at their critical moment and to create a solution that will support their production for a long time to come.
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Come and visit us at our Jüri office at Kesk tee 10, Jüri, Rae vald, Estonia
Markland has provided full services for ships, from the construction of spaces to the installation of piping systems.
The production process produces pipe assemblies and modules suitable for installation in ships, boiler houses, power plants, offshore processing of oil products, etc.
The quality system is constantly being developed in line with requirements.
The task was to equip four adjacent welding booths with an individually controlled ventilation solution, while maintaining postcrane serviceability in each booth. In addition, it was important to reduce energy costs and optimise system operation.
For this project, we used the Danish manufacturer Gram Clean Air's FL series welding filter, which is now one of the most common filters for various solutions and was ideally suited for this project.
Each welding booth was equipped with a stand-alone "push-pull" with a solution. We designed the system based on the following principles:
Individual control - when the welding process is started, the valves of the corresponding welding box are opened. At the end of the welding operation, the operation of the corresponding zone is shut down after the post-weld time has elapsed.
Air exchange control - depending on the number of active workstations, the automation controls the fan speed.
Calculations of airflow rates, velocities and head direction to ensure the most efficient exhaust and correct equipment selection.
By optimising consumption, we ensure reduced maintenance costs and energy efficiency.
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Birger OÜ specialises in the design and manufacture of HL-type containers. Located in Avinurme, Estonia, the company has 12 500 square metres of modern production space and 10 000 square metres of warehouse space. Their product range includes different types of containers to meet the needs of each customer.
A customer contacted us expressing concerns about their production process where insufficient humidity was observed. In particular, the humidity in the production area had dropped below 20%, which had a significant impact on the paint drying rate and thus the overall production efficiency.
The client wanted to have a system that was as simple, affordable and reliable as possible. Solving such a problem requires a precise and considered approach. Our team carried out thorough calculations to find the best possible solution.
Our aim is always to ensure that our customers get the best results from their production processes. Committed to quality service and efficient solutions, we are proud to have been able to address this challenge and help our customers achieve the desired result.
To achieve the goal, we installed in the customer's production premises. UNIFOG irrigation system. Taking into account air traffic and air volumes, we developed an efficient solution with a single zone. This system is specifically designed for industrial conditions, offering flexibility and efficiency.
We added remote control to the system, allowing the customer to monitor the real situation in production and make changes if necessary.
In addition to the irrigation system, we also installed a. water cushioning systemto ensure quality water for irrigation equipment. This ensures smooth system operation and helps keep maintenance costs low.
Any ideas that could be reviewed together? Contact us
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Harmet Metall specialises in the manufacture of metal structures. Their production process makes extensive use of metal welding, which in turn produces a huge amount of blue "welding fumes" that fill the production hall.
As the production process used large parts that were manipulated during the work, it was not possible to create a specific point system for smoke extraction. The most sensible approach was therefore to use GramCleanAir a solution for welding filter towers.
After with demo the customer wanted to buy two filter towers for their production to help keep the environment cleaner.
Harmet Metalli and our team worked together to find a suitable solution for removing welding fumes from the production line. The filter towers help to maintain good air quality and ensure a safe and healthy working environment for welding workers.
We are proud to have been part of Harmet Metal's efforts to optimise their production processes and improve the working environment. Our experience and expertise helped them to find an efficient and sustainable solution that meets their needs.
Any ideas that could be reviewed together? Contact us
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March 2022 brought a new chapter in Estonia's industrial landscape when Tammer approached Elister for a bid for an innovative powder coating line. The aim of the project was to provide a high quality surface coating by powder coating that would meet Tammer's high quality standards as well as their vision.
Together with our partners Gema and Aabo-Ideal, whose sole official representatives we are in Estonia, we developed a preliminary plan. We then fine-tuned it with Tammer to ensure the best possible solution.
We had to overcome several competitors to complete the project, but in the end we came out on top. The contract was signed by the end of 2022, which meant that we could start the installation works in May 2023. Thanks to the dedicated work of the team, the whole installation was ready before Midsummer.
Tammer's new automatic line includes a unique baking oven from Danish manufacturer Aabo-Ideal, which has both gas and electric heating capability - something you won't find in any other powder coater in Estonia.
The paint booth comes from the Swiss manufacturer Gema and is equipped with 16 automatic spray guns, which guarantee a high-quality paint result even at high speed. The products are moved by a monorail conveyor with a load capacity of 100 kg per metre.
In addition, we helped Tammer build compressed air ducts and ventilation duct outlets, ensuring a smooth and efficient production process.
You can read more about Tammer's investment on their website: Tammer invested one million in a new powder coating automation line.
We wish Tammer many trouble-free years of production and a quick return on investment, confident that their new powder coating line will bring great progress and innovation to the Estonian industrial sector.
Any ideas that could be reviewed together? Contact us
Come and visit us at our Jüri office at Kesk tee 10, Jüri, Rae vald, Estonia
BMF (OÜ Lisako) started its activities in 2001 and their wide range of products covers the needs of very different customers - from hobby farmers to forestry professionals.
BMF is one of Europe's largest manufacturers of forestry trailers, whose success is based on high-quality products designed in accordance with Estonia's long forestry tradition.
Improve the quality and safety of the welding environment by optimising the existing ventilation system.
The client's previous solution, a "Push-Pull" ventilation system, was inefficient and needed to be revised - despite the system's existence, it did not clean the air in the plant.
There was a complete lack of stimulation in the robotic area, which led to a decline in the quality of the working environment.
We installed special cubes in the robot work areas to completely cover the area of the working robot. This ensures that fumes from the welding process are effectively removed. As cantilever cranes are actively used in the work, we could not use slats or curtains on the cubes, which would have further improved the result.
In addition, we equipped the robotic system with pressure control, which ensures that the alarm is only active when the robots are working and on an as-needed basis. This not only increases efficiency, but also helps to save energy costs.
On the existing "Push-Pull" system, we found that the system piping had been incorrectly calculated, which meant that the system was not working properly. We carried out a major rebuild of the system, including a redesign of the piping, which resulted in the system functioning correctly.
Any ideas that could be reviewed together? Contact us
Come and visit us at our Jüri office at Kesk tee 10, Jüri, Rae vald, Estonia
Galv-Est AS is known as one of the leading hot dip galvanizing companies in Estonia. Starting its journey in 2004, the company has grown to become a major player in the metal industry sector. A source of particular pride is their largest zinc smelter in the Nordic countries, which enables them to offer a wide range of high-quality services.
Galv-Est AS was faced with a challenge that is fairly typical in the hot dip galvanizing process: a large vacuum in the plant, created by the air being extracted from the zinc bath. The problem was not only the air flow of 45 000 m³/h, but also the fact that a significant amount of heat energy was lost in the process.
In addition, it was necessary to take into account the corrosive effects of zinc fumes and dust, which makes finding a solution even more complex.
Our solution was twofold: heat recovery and vacuum compensation. We chose a plate heat exchanger ventilation unit specifically designed with high heat exchange efficiency and specially machined elements to withstand the corrosive environment. Thanks to this device, it was possible to use the heat energy from the hot clay efficiently, even at temperatures as low as -25°C, without the need for additional heating.
In addition, we optimised the piping system by choosing stainless and acid-resistant materials to ensure long-term reliability.
The automation has been designed to synchronise the operation of the zinc bath and the fans in our system, ensuring optimal compensation of air volumes as required.
Any ideas that could be reviewed together? Contact us
Come and visit us at our Jüri office at Kesk tee 10, Jüri, Rae vald, Estonia
EKT Teed OÜ is a fast growing company, which aims to provide high quality built and maintained roads.
maintained roads and streets.
The company is faced with the challenge of ensuring clean roads and safe traffic conditions in all weather conditions. In order to perform this task effectively, the company has a large fleet of equipment and machinery that requires regular maintenance and repair.
The aim is to implement modern colour space technology in the technical maintenance processes of EKT Teed OÜ, with the aim of achieving a number of significant benefits. Firstly, modern colour space technology helps to maintain the exterior appearance of the machinery/equipment, thereby also ensuring resistance to weather conditions.
EKT Teed OÜ has adopted cutting-edge solutions to increase the efficiency of its colour space.
Any ideas that could be reviewed together? Contact us
Come and visit us at our Jüri office at Kesk tee 10, Jüri, Rae vald, Estonia
Palmse Mechanical Workshop (PALMS) is a family business established in 1992 by father and son. Today, PALMS is Europe's largest manufacturer of forest excavators and cranes. This leadership has been achieved through hard work and continuous product development.
In 2016, the Palmse Mechanical Workshop invested in a powder coating automation line with KTL washing baths. The entire line is served by a Power&Free conveyor system, which has a huge variety of sensors to function.
In 2022, we received information that the Palmse Mechanical Chamber was concerned about the functioning of the system, and by that time various companies had tried to get the system working, but without success. Considering the fact that Ideal-Line a Aabo joined in 2019, with Elister OÜ as their official representative in Estonia, we were approached in a last ditch effort to get the system up and running.
After reviewing the system and a thorough analysis, we concluded that switching the conveyor automation to the Profinet protocol might be the best way to solve the customer's problems.
After replacing the old sensors with Profinet-compatible sensors and carrying out some configuration work, the system has worked flawlessly to date. This solution has ensured a stable and reliable communication in the system, giving customer satisfaction and ensuring the downtime-free operation of the line, which until now had caused major material losses.
Any ideas that could be reviewed together? Contact us
Come and visit us at our Jüri office at Kesk tee 10, Jüri, Rae vald, Estonia
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