Case Study: Optimized Paint Booth for Roll-On Epoxy Coatings for Metal Components in Assembly Line

Project Overview

A manufacturer required a controlled enclosure to support their manufacturing process specifically for rolling epoxy coatings onto metal components as part of an assembly line operation. Unlike traditional spray applications, the roll-on method significantly changes airflow requirements, and they needed a solution precisely engineered to their process rather than a standard spray booth configuration.

The Challenge

• Epoxy is applied by rolling, not spraying, and standard spray booth sizing would over-engineer the system.
• Proper VOC ventilation required, despite reduced airborne particulate generation.
• Controlled airflow across the work surface needed to maintain safe conditions.
• Integration into a flexible, linear manufacturing space was required.

The Solution

Duroair designed a 10’H x 20’W x 50’L retractable DuroRoom™ enclosure, paired with a 13,500 CFM exhaust system specifically sized for roll-on epoxy application. Rather than defaulting to spray booth CFM calculations, Duroair’s engineering team right-sized the airflow to match the actual contaminant load, delivering a cost-effective, energy-efficient solution. A future upgrade path to 25,000 CFM was also included, should Fulcrum transition to spray application.

System Specifications

• Enclosure: 10’H x 20’W x 50’L DuroRoom™ Retractable
• Exhaust System: 13,500 CFM sized for roll-on application
• Design: Retractable system integrates into linear assembly workflow
• Future Upgrade: 25,000 CFM AHU recommended if spray application added
• Engineering Basis: Airflow calculated for rolling application, not spray

The Result

• Right-sized airflow precisely matched to roll-on epoxy process requirements
• Safe VOC ventilation maintained throughout all production operations
• Energy efficiency improved through avoidance of oversizing
• Assembly line integration seamless enclosure aligned with workflow footprint
• Future flexibility upgrade path to spray application included in design

Why This Project Matters

This installation demonstrates Duroair’s ability to:

• Engineer airflow based on actual coating method rather than defaulting to standard spray booth sizing.
• Differentiate technically between spray and roll-on application requirements.
• Prevent over-engineering and unnecessary capital expenditure for clients.
• Deliver retractable solutions that integrate into flexible manufacturing environments.