Construction Machinery

Customized Manual and Automatic Powder Coating System for Excavator Components

1. Project Information

Project: Shandong Lipai Excavator Powder Coating Line
Customer: Shandong Lipai
Location: Shandong, China
Application: Excavators & Heavy Equipment Components
Coating Process: Pretreatment + Drying + Manual & Automatic Powder Spraying + Curing
System Type: Manual and Automatic Powder Coating Production Line

2. Project Background

Shandong Lipai manufactures excavators and related heavy equipment components, including large welded steel structures, frames, covers, brackets, and other fabricated metal parts.

These workpieces vary in size, shape, and surface structure. Some areas require consistent automatic spraying, while complex shapes, corners, recessed areas, or specific workpiece sections may require manual spraying.

Based on these characteristics, ZHYAO designed a powder coating line combining automatic and manual spraying processes.

3. Customer Requirements

The project needed to address several practical coating requirements:

• Handle large and heavy excavator components
• Accommodate workpieces with different sizes and structures
• Provide suitable surface pretreatment before powder coating
• Combine automatic spraying with manual touch-up or supplementary spraying
• Improve coating coverage on complex and difficult-to-reach areas
• Reduce unnecessary manual work during material handling
• Connect pretreatment, spraying, curing, and cooling into an organized workflow

4. ZHYAO Solution

The production process was arranged as:

Loading → Pretreatment → Drying → Automatic & Manual Powder Spraying → Powder Recovery → Curing → Cooling → Unloading

The automatic and manual spraying areas work together according to the characteristics of the workpieces.

Powder Coating Process

After pretreatment and drying, the workpieces enter the powder spraying section. Automatic spraying is used for suitable surfaces and repeatable coating areas, while manual spraying allows operators to supplement areas that require additional coating access.

This combination provides more flexibility for excavator components with different geometries.

Workpiece Size and Structure

Excavator components are often large welded structures with different dimensions and surface configurations.

The conveyor, hanger arrangement, spraying area, and oven were considered according to the actual workpiece characteristics. The system allows different components to move through the same overall coating process while retaining flexibility in the spraying stage.

Manual and Automatic Spraying

The key feature of this project is the combination of automatic and manual powder spraying.

Automatic spraying can handle suitable surfaces and repeated coating areas, helping maintain a consistent spraying process. Manual spraying provides additional flexibility for corners, edges, recessed sections, and areas that are difficult for automatic equipment to access.

This arrangement is particularly practical when one production line needs to handle excavator components with different structures.

Conveyor Arrangement

The conveyor connects the main process sections and reduces repeated manual movement of large workpieces.

Workpiece spacing, hanger configuration, conveying height, and clearance were considered according to the size and weight of the excavator components.

Factory Layout

The line was arranged according to the customer's workshop conditions, with the pretreatment, drying, powder spraying, curing, cooling, loading, and unloading areas connected through a practical conveyor route.

The manual and automatic spraying sections were also positioned to support smooth workpiece movement and convenient operation.

5. Project Outcome

The completed system provides Shandong Lipai with a flexible powder coating workflow for excavator components of different sizes and structures.

The combination of automatic and manual spraying allows suitable areas to be handled automatically while retaining manual flexibility where workpiece geometry requires additional coating access.

The integrated conveyor system also reduces repeated handling of large components and connects the main coating processes into a more organized production flow.

6. Why Do Excavator Components Need Powder Coating?

Excavator components are mainly fabricated from steel and require appropriate surface preparation and coating to provide protection and a consistent finished appearance.

For large welded structures, the coating process needs to consider not only surface preparation and curing, but also workpiece size, geometry, conveying, and spray accessibility.

A combination of automatic and manual powder spraying can provide flexibility when different excavator components need to be processed on the same coating line.

7. Request a Customized Powder Coating Line

Send us your workpiece photos or drawings, dimensions, weight, production requirements, and workshop information. ZHYAO can design a powder coating system based on your actual products and production conditions.

8. Project Summary

The Shandong Lipai excavator powder coating line combines automatic and manual powder spraying within an integrated production process.

By matching automatic spraying with manual spraying, the system provides both process consistency and flexibility for large excavator components with different shapes and structures. Pretreatment, drying, spraying, curing, cooling, and conveying are connected to form a practical coating workflow.