The Problem with Traditional Industrial Spray Booth Systems
A standard industrial spray booth system works on a simple principle: it extracts air to remove overspray and pumps in clean, heated air to cure the product.
The inefficiency arises when this process is static. In older systems, the fans and burners run at a constant high rate, regardless of whether a component is being sprayed or the operator is reloading a jig.
This leads to:
- Wasted Heat: Expensive gas or electricity is used to heat air that is immediately extracted and dumped into the atmosphere.
- Excessive Motor Load: Fans running at full speed unnecessarily increase electrical consumption.
- Higher Maintenance: Constant high-load operation wears out belts, motors, and filters faster.
How Smart Airflow and Heat Recovery Change the Game
To combat spray booth running costs, Unitech Machinery designs turnkey finishing solutions that prioritise efficiency. By integrating intelligent controls and recovery systems, our energy efficient spray booths can significantly reduce the cost per part.
1. Smart Airflow Control (Standby Modes)
Modern Unitech booths feature automated standby modes. When the system detects that the spray gun has not been triggered for a set period, the booth automatically ramps down.
- Fan speeds are reduced.
- Airflow drops to a safe idle level.
- Burners modulate to maintain temperature without aggressive firing.
As soon as the operator picks up the gun, the system instantly ramps back up to operational levels.
2. Modulating Burners
Unlike “on/off” burners that cause temperature spikes and waste fuel, our systems use modulating burner arrangements. These constantly adjust the firing rate to match the exact load required, ensuring precise temperature control for curing ovens and dry-off cycles while using the minimum amount of gas.
3. Heat Recovery Systems (Paint Finishing Heat Recovery)
Why let valuable heat escape? Our paint finishing heat recovery units capture thermal energy from the exhaust air and use it to pre-warm the incoming fresh air. This simple thermodynamic exchange can reduce the burner load significantly, especially during colder UK winter months.
4. LED Lighting Integration
It may seem minor compared to gas consumption, but lighting plays a role. We equip our booths with high-output LED lighting, which offers up to 10 times the lifespan of fluorescent tubes and ensures better colour-matching visibility for your operators.
Comparison: Legacy vs. Smart Systems
| Feature |
Traditional Booth |
Unitech Smart Booth |
| Airflow |
Constant 100% Speed |
Variable (Standby Modes) |
| Burner Control |
On/Off (Spikes in usage) |
Fully Modulating (Precise) |
| Heat Management |
Exhausted to Atmosphere |
Heat Recovery & Recirculation |
| Lighting |
Fluorescent Tubes |
High-Output LED |
Retrofit vs. New Build: Which is Right for You?
We often speak to Production Managers who assume they need a brand-new facility to see energy savings. That is not always the case.
While a new turnkey system offers the highest possible efficiency, Unitech Machinery can often retrofit existing plants with modern controls and burner upgrades.
- Retrofit: Ideal for facilities with structurally sound booths but outdated controls. We can upgrade your control panel, install inverters on fans, and replace burners.
- New Build: Perfect if your current capacity is limiting production or if the existing structure is inefficiently insulated.
The Importance of Maintenance on Efficiency
Even the most advanced spray booth will lose efficiency if not maintained. Clogged filters force extraction motors to work harder to move the same amount of air, driving up electricity usage.
Ensuring you have a regular schedule for replacing your Dry Filter or Water Wash consumables is the simplest way to keep energy costs down. Unitech offers comprehensive service packages to ensure your plant operates at peak performance year-round.
The ROI of Upgrading Your Finishing Line
Investing in a new industrial spray booth or retrofitting an existing oven is a capital expenditure, but the Return on Investment (ROI) is often faster than expected.
By reducing gas consumption by up to 30% and electricity usage by 20-50% (depending on usage patterns), a modern Unitech system protects your business against volatile energy markets.
It is also worth consulting resources like The Carbon Trust regarding energy efficiency best practices, as aligning with net-zero targets is becoming increasingly critical for the UK supply chain.
Frequently Asked Questions
How much energy can I save with a Smart Spray Booth?
Typically, our clients see gas savings of up to 30% and electricity savings of 20-50%, depending on how often the booth is in “standby” mode versus active spraying.
Can you retrofit heat recovery to my existing booth?
Yes, in many cases we can add heat recovery modules to existing extraction stacks, provided there is sufficient physical space and the fan capacity can handle the slight change in pressure.
What is the payback period for these upgrades?
While it varies by usage, with current UK energy prices, many customers see an ROI (Return on Investment) in as little as 18-24 months.
Summary
You don’t need to choose between high-quality finishing and low operational costs. By leveraging smart controls and heat recovery, your paint line can become an asset rather than a liability.
Are you looking to reduce your facility’s energy footprint?
Contact Unitech Machinery today for a consultation on our energy efficient spray booths and turnkey finishing solutions.
