Lighting Hardware Powder Coating Line
Project Background
The client is a known lighting manufacturer in Egypt, producing street lights, garden lights, and landscape lights. Small order batches and many varieties — the traditional flow line lacked flexibility.
The Challenge
Lighting industry: 500+ SKUs, small order batches (200-2,000 pieces typical), frequent color changes needed. Lighting structures are complex (poles, heads, decorative parts) — coating uniformity is challenging.
MUSI's Solution
MUSI proposed a quick color-change powder coating solution: modular line + fast color-change booth (10-min change) + auto + manual touch-up combination spray stations. Total length only 50 m, but flexibility is exceptional.
Equipment Configuration
| Line type | Overhead chain + modular powder coating |
|---|---|
| Color change time | 10-15 minutes |
| Spray stations | Auto 4 stations + manual touch-up 2 stations |
| Powder hoppers | 8 independent hoppers |
| Chain speed | 0.6-2 m/min (VFD) |
| Max workpiece | Pole 6 m, base 800×800 mm |
| Annual capacity | 800,000 pcs |
| Min batch size | 200 pcs |
Implementation
60-day delivery. The client's existing line had been running for 12 years; the new line was installed in the same workshop, requiring careful scheduling around ongoing production.
Results
Color change efficiency improved 4x, small-batch order delivery time reduced 50%. The client won several premium lighting projects in Middle East landmark developments.
Client Feedback
"Fast color change is the hardest part of lighting manufacturing. MUSI's solution lets us produce lighting like clothing — orders no longer constrained by batch size."
— 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.