Case Study: Outdoor Fitness Equipment Coating Upgrade
Summary
A conversion of a solvent-based liquid line to powder coating for an outdoor fitness equipment exporter in Saudi Arabia selling to 50+ countries, completed in a 15-day holiday shutdown with equipment prefabricated during normal production. The existing pretreatment, overhead chain and load stations were kept; a powder booth, bridge oven and recovery system were added. VOC emissions fell from 200 mg/m³ to ≤10 mg/m³, energy use fell 22%, and the powder finish passed 1,000+ hours salt spray with three years of outdoor validation since. Figures as reported after the 2023 changeover.
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 |
Equipment used on this line
- Automatic spray coating lines — overhead chain, floor belt and robotic flexible lines
- Powder coating systems — electrostatic booths, vertical lines, quick colour change and powder recovery
- Liquid spray lines — water-based, solvent-based, electrostatic and 2K mixing systems
- VOCs and environmental equipment — RTO, RCO, activated carbon, zeolite rotor and wastewater treatment
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
Selection logic: why this configuration
Powder coating was chosen over an RTO on the existing liquid line because it removed the VOC source instead of treating it and gave the outdoor weathering the products lacked. The pretreatment and conveyor were kept rather than replaced because they were serviceable and the 15-day window did not allow civil work. A bridge oven was specified so the retained chain route could pass through without a new pit.
Scope of supply and key components
| Item | Specification | Notes |
|---|---|---|
| Powder booth | Automatic guns with manual touch-up | Replaced the liquid booth |
| Powder recovery | Cyclone with after-filter | |
| Curing oven | Bridge gas oven | Gas piping reconnected |
| Retained equipment | Pretreatment, overhead chain, load/unload | Inspected and reconnected |
| Fire safety | Booth and oven interlocks re-certified |
Key components
Key components are available from international brands, configurable per customer specification, so that spare parts can be sourced locally over the life of the line. Brand names below are the usual options for this type of equipment; the brands actually fitted are fixed in the contract specification.
| Component | Brands available on request |
|---|---|
| Automatic powder guns and powder feed | International tier-one powder spray gun brands |
| Oven and dryer gas burners | Riello RS series, Weishaupt monarch WM-G, Baltur TBG, Honeywell Maxon OVENPAK, Eclipse |
| PLC and HMI | Siemens SIMATIC S7-1500, Mitsubishi Electric MELSEC iQ-R, Schneider Electric Modicon, OMRON NX, Rockwell Automation Allen-Bradley |
| Variable-frequency drives | ABB ACS580, Siemens SINAMICS G120, Danfoss VLT, Schneider Electric Altivar, Yaskawa, Mitsubishi Electric |
| Dust collector filter cartridges | Donaldson Ultra-Web, Parker BHA, Camfil, MANN+HUMMEL |
| Explosion isolation, venting and spark detection | Fike, REMBE Q-Rohr, Firefly, IEP Technologies, BS&B Safety Systems |
| Sensors and temperature controllers | SICK, Pepperl+Fuchs, OMRON E5CC, Honeywell UDC, Yokogawa UT, ifm, KEYENCE |
Not included in the scope of supply
- Civil works, foundations and pits
- Building services up to the battery limit: power supply, gas, compressed air, water and drainage
- Local permits, emission approvals and third-party inspections
- Paint or powder supply, unless stated in the contract
Services included with every line: engineering design, manufacturing, shipping documentation, installation supervision, commissioning, operator training, warranty and spare parts.
Typical programme
The durations below are typical for equipment of this class and are given for planning; they are not the recorded schedule of this project. A complete line usually runs 90–180 days from contract to acceptance, a single unit 30–60 days.
| Stage | Typical duration | What happens |
|---|---|---|
| Site survey and workpiece review | 5–10 days | Remote review of drawings and photos, or an engineer visit |
| Layout and detail design | 15–30 days | Layout drawing, utilities list and specification sign-off |
| Manufacturing | 45–90 days | Booths, ovens, conveyor, pretreatment and controls built and pre-assembled at the works |
| Shipping | 20–45 days | Sea freight; equipment shipped in sections for on-site assembly |
| Installation | 15–40 days | MUSI supervision with the client's installation crew or MUSI crew |
| Commissioning, training and acceptance | 7–15 days | Trial runs on the client's parts, operator training, acceptance record |
Results: before and after
Figures are those published on this page; measurement party, sample size, test date and method are not on record here and are left blank rather than estimated.
| Metric | Before | After | Change | Measured by | Single / average | Samples | Test date | Method / instrument |
|---|---|---|---|---|---|---|---|---|
| VOC emissions | 200 mg/m³ | ≤10 mg/m³ | −95% | |||||
| Energy use | baseline | −22% | −22% | |||||
| Salt spray | liquid finish | 1,000 h+ | — | |||||
| Outdoor validation | — | 3 years | — |
Applicability and limits
A 15-day changeover was possible because the conveyor and pretreatment were sound and the new equipment was prefabricated. Lines whose conveyor needs replacement, or whose oven route requires a new pit, take longer, and powder coating suits outdoor fitness equipment only where the products do not need a multi-colour liquid finish.
Results shown in this case study reflect the stated operating conditions and should not be interpreted as guaranteed performance under different feed, production, environmental, or site conditions.
After-sales and spare parts
Warranty on a MUSI coating line runs from acceptance: 12 months on the complete line excluding consumables, 36 months on critical components such as motors, drives and the PLC, and 60 months on structural parts such as steel structure, ducting and oven bodies. Failures within warranty, excluding misuse, are repaired free of charge.
Support starts remotely: the service line is staffed around the clock, a preliminary diagnosis with recommendations is given within 2 hours, and where a site visit is needed an engineer reaches any major city within 72 hours. A spare-parts inventory is held at the Changzhou headquarters with same-day shipping, and customers can keep a dedicated parts stock at MUSI for emergencies. Details are on the after-sales service page.
FAQ
Can a liquid line be converted to powder without stopping production? This one was converted in a 15-day holiday period: equipment was built off-site during normal production, then teardown, installation and commissioning were done in 12 days with production resuming on the third day after the holiday.
What parts of the old line were kept? The pretreatment, overhead chain and loading and unloading stations. The booth, oven and recovery system were new.
How much did emissions fall? From 200 mg/m³ to 10 mg/m³ or less, measured after commissioning, well inside the local limit.
Is powder durable enough for outdoor fitness equipment? The powder system passed 1,000+ hours salt spray and has now been validated outdoors for three years on the client's installations.
Why did energy use fall? By 22%: the powder oven runs without solvent flash-off zones and the booth extraction is smaller than the liquid booth it replaced.
Next step: a configuration proposal for a similar line
If your parts, volumes or plant conditions are close to this project, MUSI can return a line configuration and layout proposal. To prepare it we need four things:
- Photos and dimensions of the workpieces, with weight and material
- Required output (pieces per hour or per day, and shifts)
- Number of colours and how often colour changes are needed
- Available floor space and ceiling height, with the utilities on site
Message us on WhatsApp with these details, or use the quotation form.
Provided by Lin Cong, Technical Director, MUSI Technology · Published 2026-05-02 · Updated 2026-09-30 · Last technical review: 2026-09-30
QQuestions buyers ask before ordering
quotation · price · lead time · installation · warranty
What information do you need to prepare a quotation?
Send part drawings or photos, the largest part size and weight, the material, the required output per shift, the paint or powder type and number of colours, and the available floor space, ceiling height and power or gas supply. MUSI engineers reply within 24 hours; a recommended configuration and quotation follow once your part data is complete.
How much does this equipment cost?
Budget depends on part size, throughput and the level of automation. Indicative ex-works ranges are published in our complete coating line cost guide; a configured quotation is prepared from your part data. Published indicative ex-works ranges: a complete powder coating line is roughly USD 75,000–230,000 semi-automatic, USD 200,000–600,000 for a standard automatic line and USD 600,000–2,000,000 for a high-throughput automated plant.
What is the lead time?
Standard configurations ship in 30–60 days from contract signing and down payment; custom configurations take longer. The delivery date is fixed in the contract.
Do you install and train operators overseas?
Yes. MUSI engineers carry out on-site installation and commissioning and give 3–5 days of operator and maintenance training. MUSI has delivered 800+ coating lines to customers in 36 countries.
What warranty and after-sales support are included?
12 months full-machine warranty, 36 months on critical components and up to 60 months on structural parts. International customers get 24-hour phone response and 72-hour on-site arrival; spare parts ship from the Changzhou headquarters.
Can the environmental equipment be supplied with the line?
Yes. VOC treatment (RTO, RCO, activated carbon, zeolite rotor), dust collection and paint wastewater treatment are supplied with the coating line under one contract; MUSI has equipped 50+ coating facilities whose projects all passed local environmental compliance reviews.
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.