Outdoor Fitness Equipment Coating Upgrade

Project Background

The client is a leading outdoor fitness equipment exporter (products in 50+ countries). Their existing solvent-based liquid spray line had high VOCs emissions and inadequate outdoor weather resistance — needed an upgrade.

The Challenge

The client needed retrofit completed without halting production. MUSI had only the regional public holiday period — 15 days. Retrofit also required reconnecting natural gas piping and fire safety systems — significant engineering coordination.

MUSI's Solution

MUSI's strategy: 'pre-fabricate during normal production + retrofit during holiday'. Pre-built all equipment off-site before the holiday, then completed teardown-install-commission in 12 days during holiday. Production resumed on day 3 after holiday end.

Equipment Configuration

Retrofit type	Solvent-based → powder coating
Construction days	15 (incl. teardown)
New equipment	Powder spray booth, bridge oven, recovery system
Retained equipment	Pretreatment, overhead chain, load/unload
VOCs reduction	95%
Energy	Reduced 22%
Outdoor weatherability	Salt spray 1,000h+
Project investment	Approximately $400K USD

Implementation

60 days from contract to production launch — only 15 days of on-site work. MUSI's project team worked day and night, finishing commissioning 2 days ahead of schedule.

Results

VOCs emissions dropped from 200 mg/m³ to ≤10 mg/m³ — well below the local regulatory limit. Outdoor field testing has now passed 3 years of validation. Product reputation in Middle East and Southeast Asia markets improved significantly.

Client Feedback

"MUSI's construction speed surprised us — and quality didn't suffer. We ordered another new line in our second factory last year — once again from MUSI."
— Project Manager, Client Side

Get a Similar Solution

If your industry and requirements match this case, contact MUSI to schedule a free consultation. We'll design an optimal solution based on your specific workpieces, capacity, and facility.