References

Paint Shop Reconstruction with Chemical Pretreatment Replacement

The partial reconstruction of the industrial paint shop for BASTEELOS, s.r.o. included the modernization of the chemical pretreatment system and the replacement of the original infrared oven with a new conventional hot-air gas oven. The aim of the project was to increase operational reliability, coating quality, and energy efficiency while preserving as much of the existing infrastructure as possible and minimizing construction modifications.

1 from 3

Paint Shop Reconstruction with Chemical Pretreatment Replacement

Project information

Customer	BASTELOOS, s.r.o.
Year of Realization	2025
Location	Chrást u Plzně (CZ)
Industry	engineering, Metal Manufacturing, Sheet Metal Processing
Flow profile	800 mm x 1.600 mm x 2.000 mm (w x h x l)
Technology	Třístupňová chemická předúprava Nová část vypalovací pece Řídicí systém k novým zařízením Automatické měření pH lázně, odmaštění a automatické dávkování

Project description

The line was designed for continuous two-shift operation with an emphasis on process stability and simplified maintenance.

The scope of delivery included a new stainless-steel chemical pretreatment tunnel with automatic chemical dosing and pH measurement, a 110 kW oven, intelligent door control based on product size, and an Omron PLC with remote diagnostics capability.

The technology was optimized to minimize heat losses and enable rapid implementation of the entire modernization, which was completed within approximately one month. The result is a modern, energy-efficient coating line with a higher level of automation, more stable coating quality, and significantly improved operational reliability.

Key Benefits of the Modernisation

Improved production reliability thanks to the complete modernisation of the chemical pretreatment system, a new curing oven, and a PLC control system with remote diagnostics.
Lower energy consumption thanks to a new 110 kW gas-fired oven, basalt thermal insulation, automatic doors, and an air curtain that minimise heat losses. The expected energy savings during curing are approximately 20%.
Improved coating quality and up to 15% savings in chemical consumption thanks to automatic pH monitoring and chemical dosing, ensuring stable pretreatment parameters and consistent results compared to manual control.
Lower maintenance costs thanks to the new technology, easy-access design, and advanced control system diagnostics.
Reduced unplanned downtime thanks to the replacement of key process equipment and a modern control system, with an expected reduction in downtime of 20–40%.
Lower investment costs thanks to the maximum utilisation of the existing infrastructure (utilities, foundations, and part of the technology), eliminating the need for extensive building modifications.
Short production shutdown – the reconstruction was designed to be completed within approximately one month, minimising the impact on the customer's operations.