Renovation of a Door Manufacturer's Finishing Workshop – MAKOR Automatic Line and Manual Finishing Booth
An automatic finishing solution, MAKOR SPRAY & DRY – M, was designed and installed for a Central Estonian door manufacturer, together with a manual finishing booth built by Elister. The heart of the finishing process consisted of GRACO PerformAA automatic paint guns with Merkur-series pumps, and the ventilation was interfaced directly with the Makor system, which detects the operating equipment and adjusts the working modes. The entire system was designed, installed and commissioned into working order precisely during the factory's collective holiday, resulting in an energy-efficient and safe finishing environment.
Project challenge
The goal was to implement an automated finishing solution while simultaneously creating a modern manual finishing booth. What made the project special was its timeline – the entire system had to be designed, installed and made operational precisely during the factory's collective holiday, which meant there was practically no room for error.
The core requirements of the solution were:
- professional LED lighting
- an efficient ventilation system
- a modern manual finishing booth
- LEL sensors and compressed air monitoring
- integration of the automation with the finishing line
How we built the solution
The MAKOR SPRAY & DRY – M compact spraying system was chosen as the automated finishing solution, as it is well suited to the needs of door production and ensures a stable and high-quality finishing result. The manual finishing booth was fully designed and built by the Elister team, taking into account the factory's production needs and the operating logic of the existing automatic line. GRACO PerformAA automatic paint guns together with Merkur-series pumps became the heart of the finishing solution.
Equipment used in the project:
- MAKOR SPRAY & DRY – M compact single oscillating arm spraying system that requires no operator
- automatic handling of jigs/doors with a LIFT loading/unloading device
- 4 guns and a 2 L paint tank
- GRACO PerformAA high-pressure automatic paint guns with Fine-Finish coating
- GRACO Merkur-series paint pumps
Automation and remote management
The ventilation was interfaced directly with the Makor system. The solution recognises which device is currently operating – either the automatic finishing line or the manual finishing booth – and adjusts the ventilation operating modes accordingly. In addition, LEL sensors were installed, which continuously measure the concentration of volatile organic compounds (VOCs) in the air and warn when a dangerous level is approaching, as well as compressed air monitoring, which ensures even pressure to the guns and directly affects paint quality. Both systems are integrated with the automation of the entire finishing line.
Result
The result is an energy-efficient, safe and well-functioning finishing environment, where the ventilation operates exactly as much as needed and supports production efficiency at every step. The automatic line ensures high productivity in serial production, while the manual finishing booth enables flexible handling of specially shaped, one-off or small batches. With precise design and an experienced team, all equipment was installed, tested and made operational exactly by the planned deadline – during the factory's collective holiday.
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FAQ
Frequently asked questions
Which automated finishing system was implemented in this solution?
How many guns and what paint reservoir does the system include?
How are safety and paint quality ensured?
How does the ventilation work together with the system?
Why does the solution include a manual finishing booth in addition to the automated line?
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