Project Background:
As part of Turkey's national transportation infrastructure upgrade initiative, large-scale renewal of highway safety facilities has become a priority project. Guardrails, as a core component of road crash protection systems, are required to have excellent weather resistance, corrosion protection, and uniform, aesthetically pleasing surface coatings. This project was led by a local manufacturer with an annual output of over 250,000 tons of steel guardrails. The client aimed to introduce vertical automatic powder coating technology to improve overall line efficiency within limited plant space while solving issues inherent in traditional manual spraying, such as uneven coatings, difficulty in color changes, and capacity bottlenecks.

Project Overview:
Commissioning Date: September 2024
Floor Area: Approximately 820㎡ (including auxiliary loading and unloading areas)
Coating Cycle: 22 seconds per guardrail
Annual Design Capacity: Over 1.8 million meters of guardrails (based on a standard 4-meter wave beam per piece)
Workpiece Material: Galvanized wave-shaped steel plates, vertically hung; individual piece weight approx. 32kg

Key Process Flow and Equipment Configuration:

Auxiliary Loading / Vertical Hanger System
I-beam track equipped with vertical guide slots for positioning; workers assist in vertically hanging wave-shaped guardrails onto hangers
Hanger spacing is 1.5 meters and adjustable to suit different models, including single, double, and triple wave guardrails
Proprietary guide mechanism ensures long workpieces maintain stable orientation during movement

Automatic Powder Coating Booth (Vertical Application)
Equipped with two sets of opposing electrostatic spray guns, 16 in total, arranged in two vertical levels for automatic tracking spray
Spray booth is approximately 7.2 meters long, with air curtain partitions to prevent powder dispersion
Features an automatic powder flow control system that adjusts powder volume based on workpiece speed and contour
Central control system includes pre-set process recipes for one-click product type switching

Large Cyclone + Secondary Recovery System
Powder recovery efficiency ≥97%, with reclaimed powder automatically sieved and blended with fresh powder
Secondary recovery unit uses high-precision cartridge filters with intelligent reverse-blow cleaning cycles
Integrated powder concentration monitoring and alert system enhances safety and operational management
Dust emission controlled within 10mg/m³, meeting EU environmental standards

Tunnel-Type Curing Oven
Total oven length: 15.6 meters, divided into 4 temperature-controlled zones
Curing temperature range: 180–200°C with adjustable hot air circulation to ensure uniform curing of long workpieces
Vertical curing design promotes more even hot air distribution, minimizing powder sagging or buildup
Oven doors use automated rolling shutters for improved thermal insulation and energy efficiency

I-Beam Type Automatic Conveyor System
Track Structure: Closed-loop I-beam suspension track with high-strength lifting and return sections
Drive System: Servo-driven with variable frequency control; adjustable speed from 1.0–3.2m/min
Includes independent buffer zones to allow workpiece changeover and hanger maintenance without stopping the line
Entire line is PLC-controlled with touch-screen HMI interface for real-time monitoring of equipment status, energy consumption, and output

Project Results:
Smooth coating surface with strong adhesion; average dry film thickness maintained at 90–110μm, compliant with DIN EN 13438
Overall powder utilization increased to approximately 96%, saving around CNY 190,000 in powder costs annually (based on single-color, single-shift output)
Significant space optimization: vertical operation saves about 30% floor space compared to traditional horizontal lines
Within three months of commissioning, the client fully replaced manual coating lines; automation rate rose to over 85%, reducing labor costs by approximately 40%,Currently, this project has been designated as a model intelligent manufacturing initiative by the local government and has attracted visits from several transport equipment manufacturers. The client also plans to replicate the coating process from this line to develop separate finishing lines for guardrail accessories such as posts, end caps, and brackets.