Dunphy Combustion designs, manufactures, installs and maintains a range of combustion equipment. When they approached Hutchinson’s PVC Solutions, they needed an industrial spray booth large enough to paint some of the biggest equipment they manufacture.
Because of the size of these items, a traditional permanent spray booth wasn’t the right option. Dunphy needed something much larger, while still making efficient use of the available factory floor space.
Our solution was a bespoke SprayFlex Ultimate retractable spray booth, designed specifically around their products, painting process and existing facility.
Before signing off on the project, the Dunphy team visited one of our previous installations to see a SprayFlex Ultimate operating in a real manufacturing environment. They liked what they saw and could see how a retractable spray booth could work within their own facility.
Dunphy had upcoming projects requiring large-scale industrial painting, but they didn't have a spray booth large enough to accommodate the equipment. They needed a solution quickly, and the options they had explored weren't big enough.
Large spray-painting projects also require substantial spray-booth extraction to safely control airborne contaminants and maintain the required airflow. This meant the solution couldn't just be big enough to contain the products. The extraction system also had to perform effectively across the entire enclosure.
A standard fixed industrial spray booth would have taken up valuable factory floor space even when not in use, making a retractable system the ideal solution.
Before manufacturing began, our team conducted a full site survey to ensure the retractable paint booth would meet Dunphy's exact requirements.
We assessed the available space, roof access and potential ducting routes to determine how the extracted air could be safely filtered and discharged.
Lighting was another important consideration. The materials used in our SprayFlex system allow natural light into the enclosure, but depending on the application and working environment, additional lighting may also be required to ensure adequate visibility for industrial painting.
We also worked closely with Dunphy's Health and Safety Manager to ensure the design met the relevant COSHH requirements for their painting process.
The final solution was a bespoke SprayFlex Ultimate retractable spray booth, measuring:
The retractable design allows Dunphy to create a large, enclosed painting area when required and retract the system when it isn't in use, helping them make better use of their available factory floor space.
A spray booth of this size requires a powerful and carefully designed extraction system.
The challenge was that Dunphy's warehouse already had existing pipework and services running through the area, leaving limited space for the required ducting and LEV extraction system.
Rather than asking Dunphy to relocate existing services, we designed the spray booth extraction and ducting around the existing infrastructure.
Despite these restrictions, the system was designed to achieve an airflow rate of 0.5 m/s through the booth.
This allowed us to provide the extraction performance required while creating a bespoke industrial spray booth that worked around the existing factory layout.
Following installation, the SprayFlex Ultimate retractable spray booth underwent testing to confirm the performance of the LEV extraction system.
The booth met the required LEV and COSHH performance criteria during testing, with a recorded clearance time of just 1.05 minutes.
For a retractable spray booth measuring 6 metres high, 5 metres wide and 21 metres deep, the result demonstrated what can be achieved when the enclosure and extraction system are designed together around the application.
Dunphy now has a purpose-built industrial painting enclosure capable of accommodating some of its largest equipment without permanently sacrificing valuable factory floor space.
The project is a great example of why an off-the-shelf spray booth isn't always the answer. By designing and manufacturing a bespoke retractable system tailored to the customer's products, processes, and existing facility, we can create a solution that fits within the available space.
Take a closer look at Dunphy’s bespoke retractable spray booth in the video below.
If your products are too large for a standard paint spray booth, or you don't want a permanent booth taking up valuable factory space, a retractable spray booth could be an alternative.
Our SprayFlex range can be designed around your available space, product sizes and working requirements to create a bespoke industrial spray booth solution for your facility.
Talk to our team about a retractable spray booth designed around your workspace.