Here at Pony we offer two types of paint booths, semi-downdraft and full downdraft. But what exactly is a semi-downdraft paint booth, and what are the differences between the two types of paint booth?
Semi-Downdraft painting booths are booths with special ventilation systems used in painting processes.
In SMD Paint Booths, air enters from the top of the booth and falls towards the vehicle in the painting area. Air is absorbed and discharged through filters at the bottom of the booth.
Unlike completely downdraft booths, these booths can receive air not only from the bottom of the booth but also from the sides. This creates a kind of air flow cycle inside the booth and ensures that paint particles in the environment are efficiently discharged.
1- Filtration System:
Semi-Downdraft booths usually have a 3 types of filtration system. The purpose of this system is to clean the dirty air released during different painting processes.
It usually consists of the following types:
Pre-Filters: Holds large particles.
HEPA Filters: Cleans very fine particles, even harmful substances in the air.
Activated Carbon Filters: Cleans volatile organic compounds (VOC) and bad odors.
2- Efficient Painting Area:
The design of semi-downdraft booths is optimised to increase the efficiency of the painting process. Uniform airflow provides more homogeneous painting results and ensures that the paint is evenly distributed on the surface.
3- Energy Efficiency:
Semi-downdraft booths can be more energy efficient than full downdraft systems. Because the full ventilation power provided by a full downdraft system is not needed. Instead, the airflow can be controlled and optimised.
In hazardous environments, Ex-proof (Explosion Proof) devices are crucial to prevent potential explosions. In spray booths, where flammable and explosive gases are present, it is necessary to use Ex-proof lighting cases to isolate the internal circuits of electrical devices from the external environment. Ilke Industrial Ltd. is aware of this safety concern and ensures all its spray booths are fitted with Ex-proof lighting cases. The company also uses energy-efficient LED lighting lamps to provide accurate colour temperature for painters to differentiate colours on a car’s surface without any colour distortion.
In environments where flammable and explosive gases are present, electric devices used must be Ex-proof (Explosion Proof). The Ex-proof feature of a device is achieved by isolating it from the external environment, preventing gas from entering the device’s internal circuits and avoiding the possibility of sparks that could cause explosions.
It is important to note that Ex-proof is not to be confused with spark-proof. Spark-proof mechanisms are designed to prevent devices from generating sparks due to collisions, friction, or static electricity. On the other hand, Ex-proof mechanisms prevent sparks from occurring by isolating the device’s internal circuits from potentially explosive gases.
According to the 2006/42/EC EU Machinery Directive, the EN-16985 standard, and the CE certification, all electrical devices that could come into contact with flammable gases must be Ex-proof in spray booths. In an auto spray booth, a painter requires 1800 lux lighting to differentiate colours on a car’s surface. Typically, 40 fluorescent lamps are used to achieve this level of illumination, and they are installed in groups of four within the booth.
Spray booths emit flammable and explosive gases such as thinner, solvents, cleaning chemicals, and resin. Therefore, the lighting cases used within spray booths must be Ex-proof to prevent gas from entering the cases and causing explosions. At Ilke Industrial Ltd., all spray booths are fitted with Ex-proof lighting cases.
Ilke Industrial Ltd. uses 6500 Kelvin LED lighting lamps in their spray booths. These lamps produce a 6500K colour temperature that allows the painter to see colours accurately without any colour distortion. Using lower Kelvin value lamps, such as 4000K, can cause colours to appear differently, making it challenging for the painter to differentiate between the car’s original colour and the patchwork. Furthermore, using LED lighting lamps in spray booths is an energy-efficient solution.
In conclusion, Ex-proof lighting cases are an essential feature in spray booths to ensure the safety of the workers and to avoid any potential explosions. Ilke Industrial Ltd. takes this matter seriously and uses Ex-proof lighting cases in all of its spray booths, along with energy-efficient LED lighting lamps.
This elevating platform is designed for use in big spraybooths (for train, bus, aircraft, plain, trailer etc.) but can also be put in use in other hazardous areas. The use of the platform allows a faster, safer spray application, masking or inspection and this easier and safer than is possible with ladders or scaffolding.
The controls for the operator are located in the cage of the personel lift. With the use of the 3 levers, the operator can send the cage in all 3 directions for maximum accessbility. Up/down movement is done by a pneumatic cilynder with chain, the left/right (along the object) is done by a pneumatic motor and the in/out movement is done by 2 pneumatic cylinders that move the cage to the central axe of the spraybooth.
Pony lifts complies with all safety and security regulations for lifting platforms but complies also with the regulations in the field of spraybooths. These platforms complies with the requirements for the use in explosive atmospheres (ATEX).
Personnel Lift is mounted on the side walls of the paintbooth. On the bottom, the platforms do not come in contact with the ground or grid floor.
The cage of the platform is designed to carry 1 person and his equipment. On both sides of the cage, there are doors that open on the inside, and close themselves by means of spring hinges.
You can contact us for more information (email: <[email protected]> )
Armored vehicles can be painted and coated more efficiently using large spray booths that can accommodate the entire vehicle at once. These spray booths are designed to provide an optimal painting environment and can be equipped with specialized features to ensure a high-quality finish.
Armored vehicle spray booths are specifically designed to accommodate the coating and painting of military vehicles. The booth’s skeleton system is designed with static calculations that can support the weight of these vehicles, as they tend to be larger and heavier than standard vehicles. Air flow requirements are determined based on seasonal conditions, and the air handling unit is designed to provide the necessary environmental conditions. To accommodate the structure of military vehicles, 3-axis spray booth lifts are positioned on both sides of the booth. This allows for the complete coating and painting of a vehicle in a single entry, improving efficiency and reducing downtime.
Inside the armored vehicle spray booth, two 3-axis spray booth lifts with pneumatic valves are positioned, one on the left and one on the right. These lifts have ex-proof protection class and CE certificate. The spray booth entrance and exit use a spiral door, which minimizes the usage area restrictions. The door motors have coupled gearboxes and a soft landing arrester (safety parachute) feature that is activated in possible situations such as sudden discharge or gear breakage. Additionally, the systems are equipped with a PLC, which provides ease of control and monitoring from a single point.
Our 3-axis spray booth lifts, positioned inside the spray booth, are designed to address the challenges of applying paint to military vehicles that have varying shapes and sizes based on their usage and functions. With their ability to move sideways, up-down, back and forth, and with three axes, our lifts provide superior results in paint application. The staff can control the lift basket and approach the vehicle at the right angle and distance for optimal application. This feature also ensures improved work safety when working at heights.
At our company, we prioritise the production of environment friendly spray booths that adhere to both World and European standards. Our goal is to filter harmful substances from the painting process with our spray booths, in order to protect our planet and promote sustainability.
We prioritize producing environment friendly spray booths that filter harmful substances to protect our world, in accordance with World and European standards. Despite market competition, our company continues to invest in R&D for eco-friendly approaches. Our compact active carbon filtering system filters out 80%-90% of harmful odors and chemicals. These special filters, with active granular carbon particles between two layers of filter material, provide perfect filtration and can be used in all paint application areas. Our designs achieve high efficiency from compact activated carbon filters, guaranteeing personnel health. We promise our customers not only quality painting, but also to protect nature and breathe cleaner air.
Self-healing paints represent a promising and innovative new class of industrial, marine, and automotive coatings that are generating considerable interest and excitement for their potential to revolutionise the field.
Dents and scratches are an inevitable part of life, but the cost of repairing a scratched phone can be higher than repainting your car.
What’s worse is that poor quality paint and application can lead to mechanical failures. For example, cracks in paint can lead to the tearing of aircraft and pose a risk of falling. It’s crucial to invest in high-quality paint and skilled professionals to ensure that your paint job is both aesthetically pleasing and mechanically sound.
Self-healing paints and coatings have the remarkable ability to fill gaps and restore surface scratches through a two-stage process. Firstly, they fill the gaps, and then they proceed to heal the damaged area, resulting in a beautifully restored surface.
There are various technologies used in the production of self-repairing paints, and we can broadly categorize them into five main types:
1- Hollow fibre approach
2- Reversible chemical reactions
3- Microencapsulation
4- Heat-activated thermoplastic polymers
5- Micro-vascular network
While self-repairing paints are commonly used in the automotive industry, we believe that this technology has the potential to revolutionize the spray booth industry in the future.
We are certain that we will be hearing more about this innovative technology and seeing it in repair and body shops across various industries in the near future.
Regularly replacing the intake and exhaust filters is one of the easiest and most effective ways to improve the overall efficiency of your spray booth.
Intake filters are typically located where outside or shop air is introduced into the spray booth working environment, while exhaust filters are designed to capture overspray from the booth working environment and prevent harmful particulates from being exhausted into the atmosphere by the booth’s exhaust fans. The primary function of both intake and exhaust filters is to maintain a clean and safe working environment within the spray booth, while also protecting the surrounding environment by capturing any hazardous particles that may be present. Regularly replacing these filters is critical for ensuring the continued effectiveness and efficiency of your spray booth.
In addition to improving the overall efficiency of your spray booth, regularly replacing filters can also reduce the likelihood of malfunctions occurring.
An efficient and reliable spray booth is essential for reducing production costs in your shop.
When filters become clogged or overloaded, proper airflow is hindered, which can cause dust or overspray to recirculate and compromise the quality of your paint job. By staying on top of filter replacements, you can help ensure that your spray booth operates at peak performance, minimizing the risk of costly malfunctions and maintaining high-quality results.
A manometer is a useful tool for measuring pressure differentials and can be used to determine when spray booth filters are becoming clogged and in need of replacement. By monitoring the pressure differential with a manometer, painters and service personnel can easily determine when it’s time to change the filters in the spray booth. If your spray booth does not have a differential pressure gauge, it’s important to establish a strict maintenance schedule based on the amount of time spent spraying in the booth to ensure that filters are regularly replaced and the spray booth continues to operate at optimal efficiency. Regular maintenance and filter replacement will help ensure that your spray booth consistently produces high-quality results while minimizing the risk of malfunctions.
1- The correct temperatureMaintaining the correct temperature is crucial for optimal performance in spray booths, particularly in the automotive sector where productivity and profitability are closely linked. For water-based paints, the recommended booth temperature is between 21 and 24 degrees Celsius. It’s equally important to avoid exceeding ambient temperature when using solvent-based paints. However, determining the correct temperature for industrial painting spray booths can be more complex, requiring consideration of factors such as the type of coating being used.
To ensure optimal results, it’s best to follow the manufacturer’s recommendations for temperature settings during curing. It’s also important to consider the size of the object being painted, as this can impact the time required for drying. For instance, a large bus will require more time to dry compared to a smaller vehicle due to the greater surface area that needs to be heated. By taking these factors into account and optimizing everything to UK standards, you can ensure the highest quality results in your spray booth operations
2. Saving Energy
By utilizing energy-efficient materials and systems in your spray booths, you can increase the profitability of your institution while meeting UK standards.
Our spray booths are constructed with 304 quality (309 quality optional) stainless steel sheet and feature heat exchangers produced by İlke Endüstriyel A.Ş, which provide homogeneous heat transfer. Additionally, our R&D unit is specially designed to optimize energy efficiency in our spray booths, providing shadow-free and perfectly lit environments with calculated luminous flux.
By incorporating these features into your spray booth operations, you can maximize energy savings and profitability while adhering to UK standards for spelling and units of measurement.
3. Key Compenants of Spraybooths
Understanding the components of a spray booth and their functions is essential for maximizing your spray booth’s performance. Here’s a breakdown of the most common components found in spray booths:
a. Spray booth walls
b. Spray booth ceiling
c. Spray booth doors
d. Exhaust chamber
e. Plenums (air distribution chambers)
f. Air handling units (AHUs) or fans