Wall Systems Manufacturer's New Factory Aspiration and Finishing Solution
For one of Estonia's leading manufacturers of wall systems and door panels, a complete turnkey solution was designed and built at their new factory, integrating aspiration, robotic painting, ventilation with heat recovery, and drying. A NAWARA Rubin negative-pressure filter unit was installed together with Formula Air ducting, along with the Makor Robostart P fully automatic spray line with a capacity of up to 200 doors per week. The solution enables the client to bring the entire production cycle—from milling to final finishing—into their own factory, improving quality control and reducing costs.
Project Challenge
The client had previously outsourced the production and finishing of its wooden products as subcontracting and sought greater flexibility, quality control, and efficiency. For this, it needed a complete production setup in which the aspiration, finishing, and ventilation systems would form a unified whole. Initially, Elister was only offering aspiration ductwork, but through communication it became clear that the company was able to provide an integrated solution.
How We Built the Solution
All systems were designed in accordance with the specific characteristics of the production building and the equipment layout plan, and 3D models were created so that the entire solution would be clearly comprehensible. The systems were configured to operate as an automated workflow as far as possible, and as a custom solution, drying trolleys matched to the Robostart P system were designed and manufactured, enabling the smooth movement of parts between loading, painting, and drying. Installation and commissioning were carried out by Elister's experienced technical team.
Main components of the installed system:
- Aspiration system – NAWARA Rubin negative-pressure filter unit and Formula Air aspiration ductwork, negative-pressure dust extraction together with the filter unit and aspiration lines
- Energy-efficient compact solution with automatic damper and fan control to ensure clean and safe working air at manual workstations and automatic lines
- Automatic spray line – Makor Robostart P with the LIFT 2P loading/unloading unit, 3D laser product detection and automatic finishing by robot
- GRACO PerformaAA and G40AUT automatic guns
- GRACO Merkur 24:1 paint pump with 150 cc volume
- DeVilbiss COBRA 2 low-pressure automatic guns for stain finishing
- GRACO Finex low-pressure finishing kit for smaller jobs
- Finishing ventilation with heat recovery – CIC (Czech Republic) water-heated ventilation system, automatic air exchange control according to the intensity of production and painting
- Drying room with intensive airflow and a stable temperature for uniform drying of the painted surface
- Custom-designed and manufactured drying trolleys, matched to the Robostart P system
Automation and Remote Management
A dedicated control panel with remote management was created for the finishing process, monitoring operations and keeping costs low. The ventilation is integrated with heat recovery, which reduces energy consumption, and air exchange is regulated automatically according to painting intensity.
Result
The integrated solution enables the company to bring several production stages into its own factory, achieving better quality control, reducing costs, and increasing production independence. The fully automatic spray line ensures uniform coverage on both flat surfaces and edges and is suited to small and medium series production with an output of up to 200 doors per week.
Galerii
FAQ
Frequently asked questions
What is the spraying line's production capacity?
What equipment does the spraying line include?
How is dust extraction and aspiration handled?
How does the solution keep energy costs low?
Does Elister provide a complete turnkey solution?
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