Case Study: Alloy Wheel Spray Painting Line, Indonesia
Summary
A complete spray painting line for an Indonesian manufacturer of aluminium alloy wheels for cars and motorcycles, in business since 1991 in Cikarang, West Java, supplying vehicle makers and the aftermarket including export. The line is built around a DCJ330 floor rail conveyor with chain-driven rotating carriers so each wheel spins past the spray stations, two cyclone water-curtain booths, a filtered constant-pressure air supply room with six fans, an automatic paint supply system with ten drive motors, hot-water heating, a forced cooling section with eight fans and an explosion-proof electrical control system. Equipment reached the plant in stages between December 2025 and April 2026.
Project Background
The client is an Indonesian manufacturer of aluminium alloy wheels for cars and motorcycles, in business since 1991 at its plant in Cikarang, Bekasi (West Java). It supplies both vehicle makers and the aftermarket, including export markets. MUSI supplied a complete spray painting line to the plant, shipped from China in stages between December 2025 and April 2026.
The client's home OEM market is Indonesia's vehicle industry, where the Japanese makers assemble locally and Chinese brands including SGMW Wuling, BYD, Chery, GAC Aion, MG and DFSK now also build vehicles in West Java and Banten; Chinese brands accounted for roughly 19% of Indonesia's retail car sales in January–August 2026 according to Gaikindo data.
The Challenge
An alloy wheel is judged on its finish as much as its strength. Spokes, windows and the inner barrel all need even coverage, the painted surface must be free of dust and runs, and every wheel in a batch has to match. That calls for clean, pressure-controlled booth air, steady paint delivery, and a conveyor that turns each wheel in front of the spray stations rather than presenting only one face.
MUSI's Solution
MUSI built the line around a DCJ330 floor rail conveyor with chain-driven rotating carriers, so each wheel spins as it passes the spray stations and receives even coverage on spokes and rim. Filtered supply air keeps the booths at constant positive pressure to keep dust off the wet film. Cyclone water-curtain booths capture overspray, an automatic paint supply system feeds the guns at steady pressure, and a hot-water heating system and forced cooling section control the temperatures between stages.
Equipment Scope
| Conveyor | DCJ330 floor rail conveyor with drive, connecting parts, structural sections and anti-slip devices |
|---|---|
| Wheel rotation | Floor-rail chain rotating carriers, so each wheel turns in front of the spray stations |
| Overspray capture | Two cyclone water-curtain booths, each with frame, fan, water tank, pumps and distribution box |
| Booth air | Filtered, constant-pressure air supply room with six industrial fans in an insulated panel enclosure |
| Paint delivery | Automatic paint supply system with hoses, frames and ten drive motors; spray guns including a powder gun |
| Heating | Hot-water heating system with boiler, water pumps and tanks |
| Cooling | Forced cooling section with eight industrial fans |
| Controls | Electrical control system with explosion-proof lighting |
Results
The equipment reached the plant in stages between December 2025 and April 2026, giving the client a spray painting line built around the needs of alloy wheels: rotation at every spray station, clean pressurised booth air and wet overspray capture.
Selection logic: why this configuration
Rotating carriers on a floor rail conveyor were chosen over hanging wheels because a wheel presents spokes, windows and barrel to the guns only when it turns, and floor carriers avoid hanger marks on the visible face. Water-curtain booths were preferred to dry-filter booths for the overspray load of a wet-paint wheel line, and a pressurised, filtered air supply room was specified because dust in the wet film is the main reject cause on wheels.
Scope of supply and key components
| Item | Specification | Notes |
|---|---|---|
| Conveyor | DCJ330 floor rail conveyor with drive and anti-slip devices | |
| Wheel rotation | Floor-rail chain rotating carriers | |
| Spray booths | Two cyclone water-curtain booths with fans, tanks, pumps | |
| Booth air | Constant-pressure air supply room, six industrial fans, insulated enclosure | |
| Paint delivery | Automatic paint supply system, ten drive motors; spray guns incl. a powder gun | |
| Heating and cooling | Hot-water heating system with boiler; forced cooling with eight fans | |
| Controls | Electrical control system, explosion-proof lighting |
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 liquid guns, pumps and 2K proportioners | Graco ProMix 2KS, Sames Airmix, WAGNER AirCoat, Nordson, Binks (Carlisle Fluid Technologies) |
| Automatic powder guns and powder feed | Gema OptiGun, Nordson Encore, WAGNER PEA-X1, Sames (formerly SAMES KREMLIN) |
| 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 |
| Conveyor gear motors | SEW-EURODRIVE, NORD DRIVESYSTEMS, Bonfiglioli, Siemens, Sumitomo Drive Technologies |
| Booth ceiling and intake filter media | Freudenberg Viledon, AAF SureStop, Camfil, MANN+HUMMEL |
| Sensors and temperature controllers | SICK, Pepperl+Fuchs, OMRON E5CC, Honeywell UDC, Yokogawa UT, ifm, KEYENCE |
| Compressed air for powder feed and instruments | Atlas Copco GA, Ingersoll Rand RS, KAESER ASD, Sullair |
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
- Installation labour and site utilities at the Cikarang plant
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 |
Applicability and limits
The configuration is for wet-paint alloy wheels with water-curtain overspray capture and a pressurised booth; plants specifying a powder primer and acrylic powder clear need a powder booth and cure oven in addition. Shipment dates are from the shipping records; production figures at the plant have not been published.
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
Why do wheels rotate on a wheel painting line? So spokes, windows and the inner barrel all face the spray stations in turn; a wheel that does not turn receives paint only on one face.
Water-curtain or dry-filter booths for wheels? Water-curtain booths handle the heavy overspray of wet-paint wheel lines and are easier to keep clean; dry filters suit lighter loads.
How is dust kept off the wet film? A filtered air supply room keeps the booths at constant positive pressure so unfiltered plant air cannot enter while the film is wet.
What was delivered? A complete line: conveyor with rotating carriers, two water-curtain booths, air supply room, paint supply, heating, cooling and controls, shipped from China in stages from December 2025 to April 2026.
Can the line apply powder as well? A powder gun is included for a powder stage; a full powder primer and clear system would add a powder booth and cure oven.
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.
Published 2026-09-26 · Updated 2026-09-30 · Last technical review: 2026-09-30
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Provided by Lin Cong, Technical Director, MUSI Technology