Spray booths with water curtain. Spray booths for furniture production The principle of operation of the water curtain
Basic equipment:
- Prefabricated body and standing bath made of galvanized steel with a large number of longitudinal, transverse and vertical stiffeners.
- Double cascade water curtains
Frontal curtains of both cascades (those through which water flows) have a quick-detachable design. This not only provides full access to the interior of the chamber for maintenance, but also makes it technically possible to narrow the gap between the bottom edge
curtains and water in the bathroom below. For the upper cascade, this is the lower cascade bath, and for the lower cascade, this is the settling bath.
This design has a number of advantages, the main ones being:
- due to the absence of long sections of free fall of water, the formation of splashes in both the upper and lower parts of the working area is excluded;
- water falling from the lower edge of the water curtain creates a dense stream, additionally purifying the air from suspensions, which eliminates the need to install water sprinklers;
- the air flow rate after getting inside the spray booth is reduced by 4-5 times, which allows suspensions to settle into the settling bath, increasing the degree of purification of the exhaust air.
- The location of the bath for placing the pump is universal (to the left or to the right of the chamber). In this way, the service side can be selected during installation.
- The location of the service area outside the chamber allows visual control of operation and avoiding external contamination of the pump, which leads to its overheating and premature failure.
- Gate valves located outside make it easy to regulate the flow of water in the water curtains, as well as to quickly drain water from the chamber with a regular pump during its scheduled maintenance.
- stainless steel pump,pumps clumps of sludge paintwork materials with a diameter of up to 35 mm, as well as a built-in overheating protection system.
- Circulating water conduit system, including a water circulation valve, an automatic water drain valve, all necessary hoses, passage assemblies, flanges, clamps and other installation materials
- Mounting kit including bolts, nuts, washers, sealant, etc. according to the camera package
- Packing for transportation by road
- Passport and instruction manual
- CD with diagram and photo illustrations of the assembly
Additional options:
- Exhaust fan
- Barrier panel labyrinth
- Control panel for placement outside the hazardous area
- Control board in a plastic case
- Explosion-proof luminaires with lamps (2х36 W)
- Working area depth increase by 0.5 meters (roof panel and 2 side panels)
- water floor
- Supply fan and set of filters for "economy project"
- Placement of the pump inside the chamber (to reduce the overall width of the chamber)
- Front curtains of both cascades made of stainless steel instead of galvanized steel
Spray booth with a water curtain»>A great business solution is to paint cars at home. But in order to be able to paint cars, there is little experience and equipment for painting, it is also necessary to have a room in which the painting of vehicles will be carried out. In organizations that deal with car painting, paint work has long been carried out in a chamber with a water curtain. It is no secret that such a device can be made with your own hands, only with some effort and spending a small amount of money to buy some equipment. You can buy a ready-made one, only its cost will be very high, and not everyone is ready to invest a large amount. In order to make a device with a water curtain with your own hands, you will also need some knowledge.
Spray booth with a water curtain is a closed room, which is made of stainless steel and has supply and exhaust ventilation. Such ventilation is created with the help of electric motors. The main part of the device is a heating element, which helps to heat the room to the required temperature and maintain it during painting work. The chamber also includes lighting, which must be distributed evenly over the entire area, and have sufficient luminous flux. It is best to place them not only on the ceiling of the room, but also on the side walls. The device also includes equipment for painting work, and other auxiliary tools.
Painting booth layout
Knowing what the spray booth consists of, it is necessary to determine the location where the arrangement will be made, and make a project according to the location of the main structural elements. An excellent location for the construction of the device can serve as a garage, or build a new extension, which will take more time and, accordingly, finances. To make a device with your own hands, you will need structural elements from which it will be based, heating and ventilation systems, filtration and lighting.
Scheme of a spray booth with a water curtain
Making a painting chamber
Having made the layout, it is necessary to carry out all the technical calculations, and proceed with the installation work.
First of all, a new room is being built or a frame is being assembled inside the garage. The overall dimensions should be: length 10 meters, width 8 meters, height 3.5 meters. The spray booth, respectively, has a size: 4 meters wide and 6 long.
- Gate installation.
It is best to use the gates insulated so that there is no suction and loss of warm air, the outside is sheathed with corrugated board. In the place of contact of the gate, it is insulated with a special adhesive tape. Places with cracks must be filled with mounting foam. - Floor construction. The base of the floor is made of concrete, inside which a hole is made, and a metal pipe with a diameter of 150 mm is brought out into the street to drain air. A metal grate is laid on the floor over the entire surface of the room to a height of 15-20 cm.
- Walls. The walls are sheathed with corrugated board, and inside they are insulated, you can make a sandwich panel.
- Air exchange system. Components: two electric motors and metal pipes with diameters of 100 mm and 150 mm, respectively. For supply ventilation, an electric motor with a power of 5 kW is used, for exhaust ventilation at least 7 kW.
- Ceiling. It is made of a professional flooring, with a heater. A metal frame is mounted in the ceiling for air flow. An electric heater that will supply warm air to the room is installed on the street.
- Gate installation.
- Air cleaning. It is carried out using filters and has a three-level purification.
- 1 Level. A frontal water curtain is created, which is carried out by draining uniform water flows;
- 2 Level. Cleaning the air inside the device. Promotes air filtration and purification from paint waste;
- 3 Level. dry filtration. It contributes to the complete purification of air from paint particles and performs the function of protecting the fan from paint sticking.
- Lighting. Mounted LED or fluorescent lamps on the ceiling and walls of the room.
Automatic sensors for control and monitoring of the system of supply and exhaust fans and filters are also installed.
Having mounted everything necessary for the water chamber, the equipment for painting is installed.
How the work is done
The electric heater pumps air from the atmosphere into the closed space of the room. Passing through the system, the air is cleaned by filters, each of which provides a certain purification.
The temperature in the room rises due to the work of the heaters. The painting process begins. Down on the floor, air begins to be sucked out of the chamber, with the help of an exhaust fan. Water curtains are installed in front of the highway, which help to retain paint particles. Here, the air passes through all three levels of purification, if such are pre-installed. By the same principle, cameras with a water curtain and factory production work.
Do-it-yourself positive aspects of the device
- Free planning system.
- Big savings.
- The ability to save on all components.
- The ability to use the main parts of the structure.
Device disadvantages
- There may be inaccuracies in the calculations, or imperfections in the installation of the device.
- It is not possible to automate the entire process, since the elements of the device consist of separate parts.
- There are no guarantees for the performance of such a device.
Price
The cost of building a do-it-yourself water curtain chamber can take a long time, but it will cost about $4,000. You can buy a factory one from $20,000 and up. To start a business, the best option is to do it yourself, which is much more profitable for a start-up business.
To carry out the procedure for painting a car, it is necessary to have not only suitable paint and varnish products, but also equipment. For this purpose, cameras are used for painting cars or their individual parts. Today, this equipment is produced by many industrial enterprises. Also, a do-it-yourself spray booth can be made directly in the garage.
The painting chamber is a small room in which all conditions are created for the high-quality application of any paintwork. During the staining procedure, a certain air temperature is maintained in it. The chamber is equipped with modern ventilation and filtration systems. In many auto repair shops, this camera is used quite often. It is thanks to her that it is possible to carry out all paint and varnish work at a high level.
The most optimal air circulation is created in the room. Due to this, polluted air, which is inherent in all rooms where paint and varnish work is carried out, is brought out. Before that, it goes through a filtering procedure through filters, which are usually located on the floor of such a chamber.
The advantage of using a booth for painting cars and other items is that the air filled with volatile substances, which are present in almost every type of paint and varnish product, is cleaned and only then enters the atmosphere.
The chamber is always perfectly clean. Thanks to this, at the moment of drying paint or varnish on the surface of the car, a layer of dust is not formed, which will make the appearance sloppy.
Modern spray booths have an improved look and performance. They are equipped with additional security systems. Thanks to this, they always maintain the optimum temperature for work. The automated system is able to control the level of air heating itself. When the temperature rises to the heating level required by the standard, the camera turns off the heating function by itself.
The chambers have built-in timers that, at regular intervals, remove the air with toxins from the paint outside. Thanks to this option, cases of fire hazardous situations are excluded.
In the spray booth, the process of applying paint products to the surface of cars is complex. It has several stages. The camera uses several operating modes that allow you to apply paint and varnish evenly and accurately.
Spray booth price depends on its technical characteristics and on the manufacturer. On average, a high-tech camera for painting cars can be purchased from 400 thousand rubles. In the secondary market, spray booth models are cheaper.
Today there are a large number of companies that specialize in the production of spray booths. They offer consumers various kinds of them. However, not everyone can afford to buy a camera for 400-500 thousand rubles and try to make such a device in their garage. Not many people know how to make a spray booth. The procedure for its manufacture does not belong to the category of simple.
First you need to choose the right room. It must be well ventilated and the following requirements:
- ceiling height should not be less than 2.8 meters.
- length and width should be 6 and 4 respectively.
- the room must have insulation that is resistant to the formation of fire.
- To cover the walls, it is best to use a matte white film. It must have a magnetizing effect.
- All coatings for individual areas of the room should have a matte texture.
- The space must be sealed.
Knowing these features, you can easily create a camera in your garage. This will save you a lot. After all, the purchase of the necessary materials will require small costs.
To create a camera, you will have to redo your garage completely.
Important: Care must be taken to ensure that the ventilation system is established in the room. If there is an inspection hole under the garage, then ventilation can also be done. For this, metal gratings can be used.
If there is none, then first you need to dig a small trench in the floor. Its depth must be at least a meter.
The garage, which is being converted into a car painting booth, needs to be insulated. For this, it is recommended to use mineral wool.
Lighting is important to make it as comfortable as possible. For this purpose it is necessary to use fluorescent lamps. They give an excellent level of glow.
DIY spray booth video
Do-it-yourself drawings of a spray booth
Spray booth plans.
2.
In the modern world, there are many models of cameras for painting cars. They are representatives of only two types:
- spray booths with a water curtain for air filtration,
- spray booths with dry air filtration.
Let's figure out what cameras are for painting furniture parts. Depending on how many and what sizes the parts will be painted, what paintwork materials you will work with, the necessary spray booth.
2.
- water spray booth without side walls and floor (front curtain only)
- water spray booth with active water floor
- water spray booth without floor with side walls
- water spray booth with active water floor and side walls
- water spray booth with active water floor and active water walls
- small spray booths, otherwise small-sized or laboratory for painting small products in piece production, instrumentation, 1 and 2 meters long.
Spray booth with dry filters
Due to its design, when painting in a dry spray booth, excess paint mist and polluted air are removed from the paint application area, while cleaning it. All this works with the right choice of fan.
What Happens When a Spray Booth Works with Dry Filters
During the operation of a dry spray booth, the following processes occur:
- removal of paint particles and dust from the spray area
- removal of paint aerosol, while preventing its spread to adjacent rooms
- conditions are provided for obtaining a high quality paint and varnish coating
- the air that is removed from the painting area is cleaned of mechanical paint particles that remain in the filters and is released into the atmosphere.
How is air filtered in a dry spray booth?
The air flow, which is contaminated with paints and varnishes, with the help of a fan moves by inertia into the chamber opening, where one or two filters.
What are dry booth filters?Filters for a dry spray booth are: Cardboard filterThe principle of operation of the cardboard filter is as follows - particles of paint and varnish hit the inner wall of the filter several times and settle on it, and the air continues to move by inertia, while there is no loss of air velocity during suction. An example of calculating the filtering capacity of a dry filterFor example, you have a dry spray booth 2 meters long with a suction area of 3.6 sq.m. This area corresponds to two pieces of a cardboard filter 0.9 meters high and 2 meters wide. The filter holds about 15 kg of paint per 1 sq.m. It turns out that the filter of our spray booth will hold 54 kg of waste paint. To calculate, we simply multiply the holding capacity of the filter by its area: 15 kg / sq.m. * 3.6 sq.m. = 54 kg. Glass fiber filterThe glass fiber filter is made of fluffy woven fiberglass impregnated with a special compound. The filter retains paint mist particles. The glass fiber filter can be used as the only or second level of air mist removal. In the variant of the second level of filtration, this filter is installed behind the cardboard filter. Often, a glass fiber filter in a roll is installed on the floor in car chambers, hence its second name is “floor”. The service life of such filters is short, only 60 hours of coloring. |
How long does a dry booth filter last?This issue, undoubtedly, in addition to the technological part, also has an economic component. The calculation of the "lifetime" of a dry filter is based on the following components:
Dry filter lifetime calculation exampleFor example, you again have a 2-meter dry painting booth, the consumption of paintwork per shift is 20 liters per day (excluding solvent), you use a paint sprayer with a traditional spray system, the material transfer coefficient is 40-45%, that is, 8 liters out of 20 liters of paint flies into the fog. Ours showed that it can hold up to 54 kg of paint. It turns out that one filter change is enough for 54/8 = 6.8 days, that is, for about a week of work. And if you bought a filter roll, then it will last for a month, and you can count it yourself in money. |
Spray booth with water curtain
Spray booth with water curtain ensures the maximum level of cleanliness and dust removal in the painting area. All this allows you to create ideal conditions for obtaining a high-quality glossy paintwork.
The frontal water curtain captures the paint mist, and the airflow created by the fan additionally draws in polluted air.
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| Video. 2. Spray booth with water curtain |
What Happens When a Water Curtain Spray Booth Works
During the operation of the water spray booth, the following processes occur:
- removal of paint particles and dust from the spray area
- removal of paint aerosol and elimination of the possibility of its spread to the surrounding premises
- providing ideal conditions for creating high quality coatings
- the removed air is cleaned of mechanical particles of paint and part of aerosol vapors and is released into the atmosphere.
How to maintain a spray booth with a water curtain?
The first thing to do when operating a water curtain chamber is to change the water. Change it depending on the degree of contamination in the cabin.
How quickly the chamber becomes dirty depends both on the intensity of painting, that is, how much paintwork is applied per shift, and on the spray guns used. On spray guns with a low material transfer coefficient, a lot of paint goes into fogging, which means more settles in the cabin. If the water is dirty, then it captures paint mist and dust worse.
How is water cleaned from paint in a spray booth with a water curtain?
In small factories, water is simply poured into the sewer, which is basically impossible, and the accumulated paint at the bottom is scooped out with shovels and other improvised means.
At "advanced" firms, coagulants and a collection of paint and varnish waste are used to remove paint. The addition of a coagulant makes it possible to turn the paint into flakes that precipitate or float to the surface as flakes. The flakes are removed manually or with a waste collector.
How is the air cleaned in a spray booth with a water curtain?
Water spray booths have three levels of air purification from paint:
- At the first level, air purification is carried out using a frontal water curtain. A stream of water flows down this part of the chamber in a continuous and continuous stream.
- At the second level, internal air purification takes place, here the main filtration and purification of air from paint waste takes place. Depending on the design of the spray booth and the manufacturer, there are various systems for internal air purification.
- At the third level, dry filtration is carried out - the air is cleaned of the remaining paint particles and protects the fan blades from paint sticking.
Schemes of structures of water chambers
Different manufacturers of spray booths have different filtration systems, for example, we give several schemes of water spray booths.
What length and width to choose a spray booth?If the maximum length of the parts to be painted is 2.7 meters, then the required cabin length is 3 meters, and if it is 1.8 meters, then 2 meters are needed. If you want two painters to work in the cabin, then multiply the numbers by two, at least. The depth of the cabin depends on the size of the room in which the painting will be carried out. If the painter is inside the cabin, then be guided by the maximum dimensions of the parts to be painted. If the room, for example, is 4 meters, and the cabin is 3 meters, then the cabin can be installed without side walls. Again, if two cabins are installed side by side, then the side walls are mandatory so that there is no spray from the adjacent chamber. |
An example of a painting booth from furniture production
Here are photos of the spray booth, which were taken during the tour at a real operating enterprise.
The use of spray booths with a water curtain allows you to improve the quality of the finish and eliminate the impact of harmful substances on humans and the environment, which is determined by various factors related to the size of the products to be painted, the volume and type of sprayed material, the duration of use of spray booths, environmental protection requirements, workers costs. For all cases, it is possible to select the appropriate spray booth with a water-filtered front suction system that ensures the sedimentation of solid particles. In this case, the product must be between the operator and the active curtain of the chamber. When choosing a stand, it is necessary to evaluate the size of the product to be painted and the need to use a cabin for the simultaneous work of several operators.
Distinctive characteristics:
- The camera is the leader in sales in Russia in this segment, occupying more than 40% of the market.
- Possessing all the necessary technical parameters, spray booths are 15-20% cheaper than analogues.
- They have all the necessary certificates for use in the Russian Federation.
- The long experience of operating this equipment in the Russian Federation (the first deliveries were made more than 5 years ago) speaks of the high quality of the metal and the low level of corrosion of the constituent elements.
- The optimal design of the chamber allows in the future to aggregate it with air injection and filtration systems to upgrade it into an overpressure chamber.
- The constant availability of equipment in stock and all the necessary spare parts allows you to immediately start operating this type of equipment and minimize the risks associated with its downtime.
- A wide product range allows you to choose the most optimal one depending on the width of the processed product or (if the product is much smaller than the width of the chamber) to use it simultaneously when working with several operators.
- To automate the painting process, the spray booth can be supplied with an automatic blank feeding conveyor (option), which leads to an increase in productivity by 2-3 times.
Basic equipment of the spray booth DF
The price of a spray booth with a pump
- load-bearing structure of the chamber, made of galvanized sheet metal.
- adapter flange for mounting the fan on the roof of the chamber
- a set of special dry filters for the aspiration unit.
- drainage hydraulic pump.
- hydraulic pump engine (Italy).
- connecting pipes and components for water circulation inside the chamber.
- frontal water curtain.
- a small raised settling tank located at the bottom of the chamber.
- fluorescent lamp - 2 pieces
- Electric control panel
- Supply voltage 380V/3/50Hz.
- mounting hardware kit.
- special electrical equipment
- further connection of an external air injection system is provided
The camera can be supplied with or without a fan. You can use your own fan of similar airflow capacity.
Compound: air aspiration unit with brass deflectors and standard motor (Italy)
- The back wall of the cascade type - the maximum spreading of water, i.e. no splashing.
- Ability to adapt to the dimensions of the room and non-standard execution.
- Fast delivery time - no more than a month.
- Constant availability of all components in stock - instant replacement in case of failure - extended warranty.
- The best prices on the market.
Convenient change of dry filters located above the water curtain.
The ability to quickly clean the camera, in an easily accessible way, as the rear lower part opens like a car hood.
A special drainage type pump in a special design that allows you to work even with water with large clots of paint.
Powerful explosion-proof fan, i.e. it is possible to work at a distance of 0.5 meters from the working area of the cab, 100% trapping of all paint vapors, preventing water dust from entering the product, the operator can work even without a mask. Even if you spray paint with a nozzle down from a meter height, the paint does not reach the floor and is completely captured by the water stand.
The principle of operation of water cabins:
With the help of a fan installed on the roof of the chamber, a vacuum is created, which ensures the suction of air, with the help of a water curtain (pos. 1), solid paint pigments are deposited. Washing with water and additional dry filtration (D) allows aerosols to be captured and deposited in the collection bath. The pump (pos.2) circulates water through the baths (A, B, C), overflowing from which forms water curtains. Some versions have two additional side curtains to optimize the first filtration stage. The chamber consists of galvanized metal panels, bolted together. Side panels and partitions are load-bearing, a centrifugal fan is mounted on the roof. Execution in various modifications: only a suction front, a suction front with additional walls and an extended roof, plus bottom baths equipped with a grate, and there are also two height options. For fine cleaning of the chemical composition of air, it is recommended to use an autonomous coal installation KARB.
Accessories for water booths available on request:
- Engine power increase from 3 to 4 hp
- Explosion Proof Motor Italy
- Active floor (depth 280 mm, width 1120 mm)
- Side water curtains (for 2 pieces)
- Free standing water filtration unit (not required as standard)
- Lamp design IP 55
- Version without roof, discount
- Version without side panels, discount for each
- Explosion and fireproof version of the control panel model "Standard-Eco"
- “Ecological” option (additional water curtain)
- Increase in working depth from 1.22 m to 1.5 m
- Increase in working depth from 1.22 m to 2 m
Specifications of DF Water Curtain Spray Booth
Characteristic name |
Characteristic value |
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External dimensions: |
2 600 |
3 100 |
4 100 |
4 400 |
4 600 |
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Working height, mm |
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Diameter of the exhaust opening on the roof of the chamber, mm |
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Extraction capacity, m3/h |
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Required fans, pcs. |
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Fan power, hp |
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Outlet, mm (L x W) |
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Outlet fixture, mm |
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Pump power, hp |
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Unassembled camera dimensions for transportation, mm: |
2600mm |
3100mm |
4100mm |
4400mm |
4600mm |
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Fan dimensions, m |
1.2 x 1.2 x 1.2 m |
1.2 x 1.2 x 1.2 m |
1.2 x 1.2 x 1.2 m |
1.2 x 1.2 x 1.2 m |
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