Painting Production Line
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In the context of global shift toward smart and sustainable manufacturing, Zhejiang Qianjiang Motorcycle Co., Ltd., based in Zhejiang, Wenling, has comprehensively upgraded the technology and environmental innovation of its frame coating production line. It has invested in the construction of a fully automated pretreatment electrophoresis production line and an industrial wastewater treatment system, aiming to achieve the following goals:
1. enhance the adhesion, uniformity, and corrosion resistance of frame coatings
2. realize automated, informatized, and intelligent management of the production process
3. ensure wastewater meets the Class B standards of “Water Quality Standard for Discharge into Urban Sewerage Systems” (GB/T31962-2015)
4. reduce comprehensive operating costs and improve resource utilization efficiency
This project focuses on the pretreatment electrophoresis coating of motorcycle frames and the supporting wastewater treatment system. By introducing automated equipment, intelligent control systems, and efficient wastewater treatment processes, it significantly enhances product corrosion resistance and quality while achieving clean wastewater treatment and resource recycling. This reflects Qianjiang Motorcycle’s strategic commitment to intelligent manufacturing and sustainable development.
The production line is designed to handle a maximum hanging size of 1200 × 800 × 1500 mm, with a single load capacity of 50 kg. It employs an overhead chain conveyor system with adjustable speed ranging from 0.5 to 3 m/min. The daily production capacity reaches 1,200 sets/day, operating on a single 8-hour shift with an equipment operational rate of no less than 90%, ensuring strong production flexibility.
The entire line comprises 26 processes, covering key stages such as rinsing, degreasing, phosphating, electrophoresis, drying, and cooling:
Pretreatment: Utilizes a multi-stage countercurrent water replenishment design, significantly saving water and improving cleaning efficiency;
Phosphating: Employs automated dosing and sludge removal systems to ensure uniform and dense phosphating film formation;
Electrophoresis: Cathode electrophoresis technology with segmented voltage control (0–250V, 150–350V), enhancing coverage in inner cavities and welds;
Ultrafiltration Recovery: Achieves electrophoresis paint recovery rates of >95%, reducing material waste;
Pure Water System: Combines reverse osmosis and mixed-bed technology, achieving a water production rate of >70% and conductivity of ≤2 μS/cm.
Tank Structure: Main tanks constructed with carbon steel and epoxy fiberglass lining for pressure resistance and insulation; phosphating tanks made of 316L stainless steel for acid corrosion resistance;
Intelligent Control: Based on Siemens S7-300 PLC and PROFIBUS-DP bus system, enabling fully automated operation and remote monitoring;
Precise Temperature Control: Electrophoresis tank temperature accuracy within ±1°C; drying oven temperature uniformity within ±5°C;
Safety Design: Incorporates multiple safety mechanisms, including leakage protection, emergency stop interlocking, and combustible gas detection.
Wastewater primarily originates from pretreatment cleaning processes, with a designed treatment capacity of 2.0 m³/h. The influent COD reaches 5,000 mg/L, and total phosphorus reaches 20 mg/L. The treated effluent must meet discharge standards, including COD ≤ 500 mg/L and total phosphorus ≤ 8 mg/L, complying with regulatory requirements for sewer discharge.
The wastewater treatment employs a combined process of physicochemical + biological + sludge treatment:
Equalization and Homogenization: Equipped with an adjustment tank for aerated mixing to balance water quality and quantity;
Chemical Demulsification and Coagulation: Dosing with PAC, PAM, and other agents to break down emulsified oils;
Co-current Flow Inclined Plate Sedimentation: Efficiently separates suspended solids and floating oils;
Dissolved Air Flotation (DAF) Unit: Removes fine particles and colloidal substances through dissolved air flotation;
Biological Contact Oxidation: Utilizes biofilm carriers to degrade organic matter and purify water quality;
Sludge Dewatering: Employs a screw press dewatering machine to process sludge into cakes for external disposal.
· High system integration, compact footprint, and stable operation;
· Low-noise fans and corrosion-resistant equipment minimize environmental impact;
· Automated chemical dosing and sludge discharge can reduce manual operational intensity;
· Sludge and clean water reuse designs reflect circular economy principles.
The project deeply integrates smart manufacturing concepts, establishing an intelligent control and data management system covering the entire process:
Central Control System: Collects real-time production data, energy consumption information, and equipment status, supporting remote monitoring and fault diagnosis;
Temperature Monitoring: 6–8 temperature monitoring points in key areas such as drying ovens, enabling real-time temperature curve plotting and enhanced process controllability;
Production Statistics: Automatically records shift production output, downtime, and emergency stop events, with data export functionality for production analysis;
Remote Maintenance: Equipment supports remote access, allowing suppliers to perform online debugging and maintenance for rapid response.
Qianjiang Motorcycle has established long-term partnerships with equipment suppliers to ensure efficient system operation throughout its lifecycle:
1. provides 7×24-hour technical support and emergency response
2. service outlets within a 300 km radius ensure on-site assistance within 12 hours
3. equipment comes with a one-year warranty and lifelong maintenance, supported by ample spare parts inventory
4. implements the "training—assessment—authorization" mechanism for comprehensive training of client operators and maintenance personnel
The successful implementation of Qianjiang Motorcycle’s frame pretreatment electrophoresis and wastewater treatment project has not only significantly enhanced quality and corrosion resistance but also achieved economic and environmental benefits. This project demonstrates Qianjiang Motorcycle’s determination and capability as an industry leader in advancing intelligent manufacturing and green production practices. It also sets an exemplary model for high-quality and sustainable development in Chinese manufacturing. In the future, Qianjiang Motorcycle will continue to deepen process innovation and intelligent upgrades, striving to build a green motorcycle manufacturing base.
In the context of global shift toward smart and sustainable manufacturing, Zhejiang Qianjiang Motorcycle Co., Ltd., based in Zhejiang, Wenling, has comprehensively upgraded the technology and environmental innovation of its frame coating production line. It has invested in the construction of a fully automated pretreatment electrophoresis production line and an industrial wastewater treatment system, aiming to achieve the following goals:
1. enhance the adhesion, uniformity, and corrosion resistance of frame coatings
2. realize automated, informatized, and intelligent management of the production process
3. ensure wastewater meets the Class B standards of “Water Quality Standard for Discharge into Urban Sewerage Systems” (GB/T31962-2015)
4. reduce comprehensive operating costs and improve resource utilization efficiency
This project focuses on the pretreatment electrophoresis coating of motorcycle frames and the supporting wastewater treatment system. By introducing automated equipment, intelligent control systems, and efficient wastewater treatment processes, it significantly enhances product corrosion resistance and quality while achieving clean wastewater treatment and resource recycling. This reflects Qianjiang Motorcycle’s strategic commitment to intelligent manufacturing and sustainable development.
The production line is designed to handle a maximum hanging size of 1200 × 800 × 1500 mm, with a single load capacity of 50 kg. It employs an overhead chain conveyor system with adjustable speed ranging from 0.5 to 3 m/min. The daily production capacity reaches 1,200 sets/day, operating on a single 8-hour shift with an equipment operational rate of no less than 90%, ensuring strong production flexibility.
The entire line comprises 26 processes, covering key stages such as rinsing, degreasing, phosphating, electrophoresis, drying, and cooling:
Pretreatment: Utilizes a multi-stage countercurrent water replenishment design, significantly saving water and improving cleaning efficiency;
Phosphating: Employs automated dosing and sludge removal systems to ensure uniform and dense phosphating film formation;
Electrophoresis: Cathode electrophoresis technology with segmented voltage control (0–250V, 150–350V), enhancing coverage in inner cavities and welds;
Ultrafiltration Recovery: Achieves electrophoresis paint recovery rates of >95%, reducing material waste;
Pure Water System: Combines reverse osmosis and mixed-bed technology, achieving a water production rate of >70% and conductivity of ≤2 μS/cm.
Tank Structure: Main tanks constructed with carbon steel and epoxy fiberglass lining for pressure resistance and insulation; phosphating tanks made of 316L stainless steel for acid corrosion resistance;
Intelligent Control: Based on Siemens S7-300 PLC and PROFIBUS-DP bus system, enabling fully automated operation and remote monitoring;
Precise Temperature Control: Electrophoresis tank temperature accuracy within ±1°C; drying oven temperature uniformity within ±5°C;
Safety Design: Incorporates multiple safety mechanisms, including leakage protection, emergency stop interlocking, and combustible gas detection.
Wastewater primarily originates from pretreatment cleaning processes, with a designed treatment capacity of 2.0 m³/h. The influent COD reaches 5,000 mg/L, and total phosphorus reaches 20 mg/L. The treated effluent must meet discharge standards, including COD ≤ 500 mg/L and total phosphorus ≤ 8 mg/L, complying with regulatory requirements for sewer discharge.
The wastewater treatment employs a combined process of physicochemical + biological + sludge treatment:
Equalization and Homogenization: Equipped with an adjustment tank for aerated mixing to balance water quality and quantity;
Chemical Demulsification and Coagulation: Dosing with PAC, PAM, and other agents to break down emulsified oils;
Co-current Flow Inclined Plate Sedimentation: Efficiently separates suspended solids and floating oils;
Dissolved Air Flotation (DAF) Unit: Removes fine particles and colloidal substances through dissolved air flotation;
Biological Contact Oxidation: Utilizes biofilm carriers to degrade organic matter and purify water quality;
Sludge Dewatering: Employs a screw press dewatering machine to process sludge into cakes for external disposal.
· High system integration, compact footprint, and stable operation;
· Low-noise fans and corrosion-resistant equipment minimize environmental impact;
· Automated chemical dosing and sludge discharge can reduce manual operational intensity;
· Sludge and clean water reuse designs reflect circular economy principles.
The project deeply integrates smart manufacturing concepts, establishing an intelligent control and data management system covering the entire process:
Central Control System: Collects real-time production data, energy consumption information, and equipment status, supporting remote monitoring and fault diagnosis;
Temperature Monitoring: 6–8 temperature monitoring points in key areas such as drying ovens, enabling real-time temperature curve plotting and enhanced process controllability;
Production Statistics: Automatically records shift production output, downtime, and emergency stop events, with data export functionality for production analysis;
Remote Maintenance: Equipment supports remote access, allowing suppliers to perform online debugging and maintenance for rapid response.
Qianjiang Motorcycle has established long-term partnerships with equipment suppliers to ensure efficient system operation throughout its lifecycle:
1. provides 7×24-hour technical support and emergency response
2. service outlets within a 300 km radius ensure on-site assistance within 12 hours
3. equipment comes with a one-year warranty and lifelong maintenance, supported by ample spare parts inventory
4. implements the "training—assessment—authorization" mechanism for comprehensive training of client operators and maintenance personnel
The successful implementation of Qianjiang Motorcycle’s frame pretreatment electrophoresis and wastewater treatment project has not only significantly enhanced quality and corrosion resistance but also achieved economic and environmental benefits. This project demonstrates Qianjiang Motorcycle’s determination and capability as an industry leader in advancing intelligent manufacturing and green production practices. It also sets an exemplary model for high-quality and sustainable development in Chinese manufacturing. In the future, Qianjiang Motorcycle will continue to deepen process innovation and intelligent upgrades, striving to build a green motorcycle manufacturing base.
