ENGINEERING CASE STUDY

Excavator Painting Line Modernization

Discover how SAFA and BESTIR collaborated to transform a manual painting process into a modern industrial finishing line, increasing production capacity, improving coating quality and reducing rework.

Before

VS

After

Customer:
Excavator Manufacturer

Industry:
Heavy Equipment

Scope:
Engineering Design, Layout Optimization, Installation & Commissioning

Partner:
SAFA + BESTIR

Key Results:
25% Higher Capacity
20% Less Rework
100% Water Recycling System
Improved Coating Quality

Project in Operation

See the Modernized Line in Action

Project Background

The customer manufactured excavator and backhoe components using an existing sand blasting line followed by manual painting. Although the production process was functional, increasing production demand, inconsistent coating quality and frequent rework created the need for a more efficient industrial finishing solution.

Working together with our international partner SAFA, BESTIR participated in the engineering, installation and commissioning of a new finishing line designed around the customer’s operational needs, available budget and future expansion plans.

Water Scarcity

Extremely limited water resources required a washing solution with minimal water consumption.

Budget Constraints

The customer required maximum performance while working within a limited investment budget.

Dust & Contamination

A dry environment and contaminated painting area resulted in poor finish quality and extensive rework.

Production Capacity

The existing manual process limited throughput and restricted future production growth.

Our Engineering Approach

Surface Preparation Optimization

Existing blasting equipment was retained while replacing sand media with reusable steel shot to improve surface quality without increasing project cost.

Manual Washing
System

A manual washing booth with a closed-loop water recycling system removed contaminants while minimizing fresh water consumption.

Wet-on-Wet Painting Process

Advanced coating technology eliminated intermediate curing, reducing energy consumption and simplifying production.

Lightweight Spray Equipment

Modern pressure-fed spray equipment improved operator comfort, coating consistency and material utilization.

Free Rail
Conveyor

A manually operated free-rail conveyor reduced operator effort while allowing future motorization when production expands.

Scalable System
Design

The complete solution was engineered with future capacity growth in mind without requiring immediate investment.

Results

30%

Higher Production Capacity

20%

Less Rework

30%

Lower Energy Consumption

70%

Cleaner Painting Environment

The modernization transformed the customer’s painting process from a labor-intensive manual operation into a cleaner, more productive industrial finishing line. Operators immediately noticed the improved working environment and significantly better coating quality during the commissioning phase.