Case Study: Plastic Parts Spray Painting Line, Indonesia
Summary
A spray coating line, about 5.4 tonnes in two consignments, for an East Java injection-moulding manufacturer of toys including dolls, action figures and educational toys with more than 20 years in the business. Spray booths with overspray capture on a cardboard dry-filter wall and a layout that keeps painted parts moving steadily from spraying to drying give every batch the same treatment, with exhaust treatment included. The line was shipped from China in May 2026.
Project Background
The client, in East Java, is a plastic injection-moulding manufacturer of toys, including dolls, action figures and educational toys, with more than 20 years in the business. MUSI supplied a spray coating production line, shipped from China in two consignments in May 2026.
The Challenge
Moulded plastic parts are light and small, and painted details must be sharp and consistent across very large batches. Dust in the film or uneven colour means rejects, and overspray has to be captured to keep the workshop clean.
MUSI's Solution
MUSI supplied spray booths with overspray capture and a line layout that keeps painted parts moving steadily from spraying to drying, so every batch receives the same treatment.
Equipment Scope
- Spray booths with overspray capture
- Part conveying between stations
- Drying section
- Exhaust treatment
Results
The line reached the client in May 2026, giving the plant a dedicated spray painting process for its moulded parts.
Selection logic: why this configuration
Dry-filter booths were chosen over water-curtain booths because toy parts are light, overspray volume is low and dry filters are simpler to run in a moulding plant. Conveying between spraying and drying was specified so painted parts are not handled while wet, which is where dust and finger marks appear on small painted details.
Scope of supply and key components
| Item | Specification | Notes |
|---|---|---|
| Spray booths | Overspray capture, cardboard dry-filter wall | |
| Part conveying | Between stations | |
| Drying section | ||
| Exhaust treatment |
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) |
| 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 East Java 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 line suits small moulded parts with light overspray; plants spraying large plastic housings at high volume usually need water-curtain booths and forced drying. 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
Dry-filter or water-curtain booths for plastic toys? Dry-filter booths: toy parts are light, overspray is low and the cardboard filter wall is replaced rather than maintained as a water system.
How are painted details kept sharp? By keeping parts moving from spraying to drying without handling, so wet paint is not touched and dust has less time to settle.
What was delivered? About 5.4 tonnes of equipment in two consignments in May 2026: spray booths, conveying, drying and exhaust treatment.
What drying temperature is safe for plastic toys? Well below the polymer's softening point; the drying section is set to the paint supplier's data for the moulded plastic used.
Is masking needed? For multi-colour parts, yes; masks or fixtures are part of the loading step and are made to the client's part drawings.
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