Conveyor Lines
The handling system is the skeleton of a plant. However well booth and oven are designed, it is the conveyor that determines how long the part stays at each stage. Once line speed is chosen, all process times follow from it — which is why handling is decided at the very start of the project.
How the process works
The chain (continuous) conveyor runs at constant speed; it is the simplest and most economical solution. All parts spend the same time in the same sequence. Where product variety is low and flow is steady, it is the right choice.
Power & free systems allow the carrier to detach from the main chain. A part can be held at a station, accumulated or taken out of sequence. This gives flexibility on lines with mixed part flow, differing drying times and manual stations; in return, mechanical complexity and maintenance load increase.
Monorail is used for light single-rail handling, while skid systems handle large, heavy parts such as bodies horizontally. Because the skid carries the part on a pallet, it leaves no hanger mark.
Buffer zones prevent a stoppage in one section from halting the entire line. A buffer between the paint booth and the oven, for example, keeps a short interruption in the booth from leaving the oven empty.
Criteria that determine the configuration
Line speed
It is derived from the target daily capacity and the number of parts per hanger. As speed rises, booth and oven length rise with it; the choice of speed therefore directly determines the building area.
Hanger capacity
The hanger’s own weight counts as much as the part weight. Hangers accumulate coating over the life of the line and grow heavier; periodic cleaning must be planned.
Hanger design
The contact point is not coated, the drainage direction governs how the paint runs, and hanger geometry decides how the part hangs in the oven. A significant share of coating defects originates from hangers.
Buffer size
How many parts the buffer holds is determined by typical stoppage durations. Too small a buffer is useless; an oversized one consumes building area.
Technical framework
| Hanger capacity | 50–5,000 kg |
|---|---|
| Line speed | 0.5–6 m/min |
| System types | Chain · power & free · monorail · skid |
| Speed control | Synchronised control with frequency inverters |
| Compliance | EN ISO 13849-1 (safety functions) |
The figures are typical operating ranges for the sector. Every line is recalculated according to part geometry, target capacity, paint system and customer specification.
Frequently overlooked points in design
- Future capacity: A conveyor cannot be sped up later; booth and oven length depend on it. If a capacity increase is foreseen, the line must be laid out for it from the start.
- Maintenance access: If safe access to chain lubrication and tensioning points is not planned into the design, maintenance is neglected and chain life is shortened.
- Emergency stop zones: Which section of the line can stop independently must be decided together with the safety architecture.
Related topics
Let’s arrange a preliminary technical discussion for a conveyor and handling system. Share your part dimensions, target capacity and paint system, and our process engineer will prepare an outline concept and budget range.