Global Surface Treatment Equipment & System Solutions — Since 2002
久昌机械
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Global Surface Treatment Equipment & System Solutions — Since 2002
久昌机械
High-Efficiency Fully Automatic Surface Coating System for Metal Workpieces
This automatic painting production line is a full-process integrated intelligent coating system. It combines five core units: pretreatment, automatic spraying, leveling and curing, online quality inspection, and VOC exhaust treatment. It is designed for high-volume standardized production needs of multinational enterprises. The complete line uses a standardized PLC intelligent interlocked control system, supports local parameter storage, fault self-diagnosis, and remote cloud monitoring, and can connect with factory MES and ERP digital management systems for full production data traceability.
The whole line uses a modular assembly structure. Conveyor options include overhead chain, floor rail, and power-and-free chain, adapting to metal workpieces across automotive, home appliance, aluminum profile, precision hardware, construction machinery, and high-end furniture industries. The equipment is supported by ISO 9001 quality management and EU CE machinery safety certification, and can meet mainstream environmental and safety standards such as EU REACH, US EPA, and Gulf GCC requirements. Complete English technical manuals, compliance test reports, and MSDS supporting documents are available for global plant construction, overseas branch procurement, and compliance audits by Fortune Global 500 enterprises.
Workpieces enter the conveyor line through the automatic loading station and complete standardized pretreatment, dewatering and drying, precision spraying, leveling, constant-temperature curing, forced cooling, and online inspection in sequence.
Pretreatment: Spray or immersion modes are available for degreasing, rust removal, surface conditioning, and phosphating, removing oil and oxide layers to protect coating adhesion from the source.
Dewatering and drying: Low-temperature hot air removes moisture and prevents coating bubbling defects.
Automatic spraying: A closed-loop paint supply system delivers coating material. Multi-axis spray guns or spraying robots apply paint at constant speed according to preset paths, with digital closed-loop control of spraying pressure, flow rate, and travel speed.
Leveling zone: Natural leveling eliminates orange peel and bubbles and improves paint surface smoothness.
Curing oven: Electric, gas, and diesel heating options are available. Full hot-air circulation inside the oven and +/-2.5 deg C temperature control accuracy support stable film formation.
Forced cooling: Rapid cooling shortens turnover time.
Online inspection: Coating thickness, appearance defects, and adhesion are automatically inspected.
Exhaust treatment: Spraying exhaust is treated by zeolite rotor or activated carbon adsorption, keeping VOC emissions below environmental limits in major global markets.
Standard process flow: automatic loading -> pretreatment (degreasing / rust removal / phosphating) -> dewatering and drying -> automatic spraying -> leveling -> constant-temperature curing oven -> forced cooling -> unloading and online inspection -> compliant exhaust discharge
Extreme production efficiency: Fully automatic unmanned operation requires very little manual intervention. Capacity is 4-5 times higher than manual spraying, supports 24-hour continuous batch production, and greatly reduces labor cost.
Standardized and stable coating quality: Digital program control manages spraying motion. Coating thickness error is only +/-2 um, the film is uniform and glossy, adhesion meets standards, and batch consistency satisfies strict factory inspection standards of multinational enterprises.
Low consumables and high economic value: Omega-style electrostatic spraying plus a closed-loop paint recovery system achieves paint utilization >=95%, significantly reducing paint purchasing and hazardous waste treatment cost, with lower long-term production cost.
Global compliance and green environmental performance: Professional VOC exhaust treatment modules are included. Emission indicators comply with environmental regulations in Europe, the United States, Southeast Asia, and the Middle East, reducing the risk of environmental shutdowns and supporting green factory certification.
Full-chain intelligent digitalization: Imported PLC central control collects temperature, pressure, paint viscosity, and capacity data in real time. One-click parameter recall, automatic fault alarm, remote online diagnosis, seamless factory digital platform connection, and full data traceability are supported.
High flexible adaptability: Compatible with water-based paint, solvent-based paint, UV paint, two-component paint, anti-corrosion primer, clear coat, and other coating types. The quick color-change system completes cleaning and color change in only 10-15 minutes and supports flexible mixed-line production of multiple workpiece types.
Energy-saving and stable process: Thickened oven insulation, waste heat recovery, +/-2.5 deg C temperature control accuracy, and closed-loop pressure and flow control keep long-duration continuous production stable with very long MTBF.
Modular flexible layout: The complete line is divided into independent modules and can be customized according to overseas plant length, width, height, and logistics passages. It has a compact footprint and suits both new plant construction and old workshop renovation.
Complete international compliance qualifications: The full line has ISO 9001 and EU CE machinery safety certification. REACH, EPA, and GCC environmental test reports, complete English technical documents, and original traceability documents can be provided for overseas factory bidding, customs clearance, and local environmental review, reducing cross-border procurement compliance rejection risk.
Digital compatibility with global smart manufacturing systems: The PLC central control system reserves standardized data interfaces and can seamlessly connect with overseas factory MES, ERP, and production traceability systems. Capacity, energy consumption, and quality inspection data across all processes are automatically stored and uploaded, meeting unified global digital control and production traceability audit requirements of Fortune Global 500 companies.
Global turnkey project delivery capability: With extensive overseas automotive and hardware coating line delivery cases for Fortune Global 500 factories, we can provide English solution drawings, overseas on-site installation guidance, localized operator training, and lifetime remote technical support. Fast global spare-parts warehouse delivery shortens overseas downtime and repair cycles.
Optimal long-term operating cost: Paint recovery rate >=95%, waste heat recovery in the oven, and stable low-failure operation substantially reduce long-term paint, power, labor, and hazardous waste disposal expenses. The modular structure supports future capacity expansion without replacing the whole line, fitting medium- and long-term expansion plans.
Flexible customization for global multi-category production: Dedicated process sections can be customized for high-end appearance parts in Europe and America, heavy anti-corrosion construction machinery parts, and long-line aluminum profile coating. The quick color-change system supports mixed-line production of multiple SKUs, allowing one line to cover different product coating needs across group subsidiaries and reducing duplicated investment.
Lifecycle warranty and global after-sales system: The complete machine has a standard warranty period, with extended warranty available for core electrical controls and heating systems. A 24-hour overseas online technical response channel, standardized English maintenance manuals, remote troubleshooting, and local engineer annual maintenance service are available to support uninterrupted multinational factory production.
|
Parameter |
Unit |
APL-15 |
APL-30 |
APL-45 |
APL-60 |
|
Hourly capacity |
pcs/h |
50-100 |
100-200 |
200-300 |
300-500 |
|
Total line length |
m |
20-30 |
40-60 |
50-80 |
60-100 |
|
Conveyor speed |
m/min |
0.5-2.0 |
0.5-3.0 |
0.5-3.0 |
0.5-5.0 |
|
Standard spray gun quantity |
pcs |
2-4 |
4-6 |
6-8 |
8-12 |
|
Standard spraying pressure |
MPa |
0.2-0.6 |
0.2-0.6 |
0.2-0.6 |
0.2-0.6 |
|
Adjustable curing temperature |
deg C |
60-160 |
60-160 |
60-160 |
60-160 |
|
Curing holding time |
min |
10-30 |
10-30 |
15-30 |
15-30 |
|
Oven heating power |
kW |
approx. 30 |
approx. 50 |
approx. 80 |
approx. 120 |
|
Finished coating thickness |
um |
20-80 |
20-80 |
20-80 |
20-80 |
|
Paint recovery utilization |
% |
>=95 |
>=95 |
>=95 |
>=95 |
|
Oven temperature accuracy |
deg C |
+/-2.5 |
+/-2.5 |
+/-2.5 |
+/-2.5 |
|
Total installed power |
kW |
approx. 40 |
approx. 70 |
approx. 110 |
approx. 160 |
Notes: 1. All model parameters are standard configurations and can be fully customized according to overseas customer workpiece size, capacity, and local energy structure. 2. The oven supports electric, gas, and diesel heating options. 3. Pretreatment processes are adjusted according to workpiece material and corrosion-protection standards of the importing country. 4. English parameter sheets and third-party test reports can be provided for overseas project bidding.
The line is designed for large-scale anti-corrosion and decorative coating of metal workpieces. It fits substrates such as steel plates, aluminum plates, tubes, castings, forgings, and metal frames, covering mainstream global manufacturing sectors including automotive parts, appliance housings, architectural aluminum profiles, precision hardware, construction machinery, high-end furniture, fitness equipment, electronic and electrical enclosures, protective guardrails, and HVAC equipment.
It can complete multi-layer coating processes such as anti-rust primer, anti-corrosion topcoat, and high-gloss clear coat. It is especially suitable for multinational factories and Fortune Global 500 manufacturing bases with high annual output, strict appearance and corrosion-protection standards, and mixed production of multiple product models.
The automatic line uses full-process digital control and is not affected by operator skill level. Coating thickness error is controllable and finished product yield is stable. Paint utilization improves by more than 40%, hazardous waste treatment cost drops significantly, and the automated line can run continuously for 24 hours. It reduces local labor management pressure in overseas factories, keeps environmental emissions compliant, and avoids penalties under local environmental regulations. Manual spraying is suitable only for very small batches of irregular parts and cannot meet standardized mass-production requirements of Fortune Global 500 enterprises.
It supports mainstream industrial coatings such as water-based paint, solvent-based paint, UV paint, and two-component anti-corrosion paint. It can match EU low-VOC water-based coatings and North American compliant industrial paint conditions. Dedicated curing programs are preset for different coatings: water-based paint at 60-80 deg C for 20-30 min, solvent-based paint at 120-160 deg C for 15-25 min, and UV paint with second-level curing. Programs can be customized according to the customer's local coating specifications.
The quick automatic cleaning and color-change system takes 10-15 minutes, with faster switching for similar colors. Three oven heating options adapt to overseas electricity prices and gas cost differences. Exhaust treatment is equipped with efficient zeolite rotor processing as standard, and VOC emissions meet mandatory standards in the EU, North America, and Southeast Asia. Third-party environmental test reports can be provided for local environmental approval.
Taking the standard APL-30 model as an example, the total footprint is about 60-120 m2. The large APL-60 model requires about 150-250 m2. Recommended clear plant height is >=5 m, with logistics and maintenance passages reserved. We can provide free online survey support for overseas plants plus 2D/3D layout drawings tailored to the customer's existing factory dimensions.
Core wear parts include spray gun nozzles, conveyor chains, heating tubes, activated carbon filter cartridges, and similar components. The machine is shipped with 10% spare wear parts and access to fast global spare-parts warehouse shipment. Remote online fault diagnosis is supported, and overseas engineers can be arranged for on-site installation, commissioning, and annual inspection. Full English maintenance manuals and standardized maintenance procedures are provided.
Customers should provide workpiece dimensions and weight, hourly capacity requirement, coating type, plant-site dimensions, local energy type, and target export market. We provide free overall solution design, English quotation, complete compliance certification documents, and one-stop turnkey project delivery.
