In industrial powder coating processes, paint stripping is often considered a secondary operation, until production continuity starts depending directly on it. For companies managing hooks, frames and coating supports on a daily basis, keeping these components perfectly clean and immediately reusable is essential to ensure coating quality, reduce powder consumption and maintain operational continuity.
This is exactly the scenario faced by a major Northern Italian job coater operating three powder coating lines dedicated to metal components of various sizes, including large structures. Six months after installation, FASTRIP T6 has become an integral part of the company’s production process, continuing to operate daily in the stripping of medium-large hooks, frames and supports. The result is a stable and continuous process capable of handling approximately 900 kg/day of stripped metal frames and supports, with an estimated productivity potential exceeding 1000 kg/day.
The challenge: handling large frames and supports
In high-productivity coating plants, hooks and frames progressively accumulate paint layer after layer. Over time, coating thickness compromises electrical conductivity, coating quality and overall process efficiency. The consequences are well known: uneven coating application, increased paint consumption, higher defect rates, production slowdowns, premature replacement of supports. As component dimensions increase, the challenge becomes even more critical. Medium-large frames and structures are significantly more difficult to manage using traditional stripping systems, especially where continuous daily operation is required. For this reason, the customer needed a solution capable of processing large supports while maintaining stable process conditions over time.
The installed solution: FASTRIP T6-300
To address these requirements, the company installed a FASTRIP T6-300 immersion stripping tank combined with ALIT METALSTRIP 2801 stripping technology. The system was specifically configured for the treatment of medium-large metal components through a controlled immersion process based on the combination of three elements: chemical action, controlled temperature, continuous mechanical agitation. The tank operates at temperatures ranging from 50°C to 70°C and uses three heavy-duty vertical mixers to keep the solution continuously moving throughout the process. Continuous agitation accelerates stripping performance and helps maintain bath uniformity, even when processing complex coatings or heavily layered supports. The process progressively dissolves, softens or detaches the paint layer from the metal substrate, preparing the components for the rinsing stage.
Operational workflow: immersion and immediate reuse
The workflow implemented at the customer’s facility was designed to ensure simplicity and industrial continuity. Hooks, frames and supports are loaded into dedicated baskets and immersed directly into the FASTRIP T6 working solution. Depending on coating type, thickness and operating temperature, treatment times generally range from one to five hours. At the end of the immersion cycle, the baskets are extracted using a lifting system and transferred to a dedicated rinsing area, where operators perform high-pressure rinsing to remove stripping residues and detached paint. At the end of the process, the components are immediately reusable inside the coating lines. This continuous cycle allows the company to maintain a constant availability of clean hooks and frames without interrupting production activities.
Real productivity data
One of the most significant aspects of this installation is that the productivity data comes directly from a real industrial plant operating daily under production conditions.
The current configuration allows processing of:
- 3 baskets per day
- approximately 300 kg per basket
- approximately 900 kg/day of stripped hooks, frames and supports
Based on the installed operational configuration, the estimated productivity potential of the FASTRIP T6-300 exceeds 1000 kg/day of stripped metal structures. Another important aspect is that the system is not yet operating at its full production capacity, leaving room for future output increases.
Thermal stability and energy efficiency
One of the distinctive engineering features of FASTRIP T6 is its thermal management system. The tank uses flat electric heating elements installed externally on the tank walls. This configuration improves operational safety by avoiding the direct immersion of high-temperature electrical components inside the chemical solution. At the same time, the absence of internal heating elements keeps the tank walls perfectly smooth, simplifying cleaning and maintenance operations. Thermal insulation is provided by a 50 mm insulating layer applied to all tank surfaces, including the bottom and pneumatic lid. The effectiveness of this insulation becomes evident during daily operation: when heating is switched off overnight with the bath at approximately 70°C, the solution still maintains a temperature of around 55°C after 12 hours. This limited thermal drop directly contributes to: improved energy efficiency, greater process stability, reduced restart times, more controlled operating conditions.
Vapour management and operational safety
The FASTRIP T6 installation also integrates a dedicated process vapour extraction system designed to improve safety and working conditions. The pneumatic lid is equipped with gaskets compatible with ALIT chemical products, minimizing vapour dispersion during operation. Before the lid is opened, the extraction system is automatically activated to evacuate vapours through a dedicated extraction collar connected to a stainless steel centrifugal fan. The system also includes a condensate separator designed to intercept and collect any condensed liquids generated inside the piping. This approach enables safer process management and improved control of the working environment.
Beyond the tank: a complete process ecosystem
The installation goes beyond the stripping tank itself and integrates several systems developed to optimize overall process management. Installed solutions include:
- automated liquid storage silos
- multifunction pneumatic systems
- water filtration and recovery systems
- process automation and monitoring
Particularly relevant is the filtration and water reuse system connected to the rinsing area.
Contaminated water is automatically collected, mechanically filtered and reused during the initial rinsing stages, contributing to lower overall water consumption while maintaining high operational efficiency. Similarly, the automated silos allow sedimentation and recovery operations for clarified liquids, contributing to reduced overall stripping chemical consumption.
A process designed for continuity
After six months of continuous industrial operation, the FASTRIP T6 installation confirms a principle that is becoming increasingly important for modern coating plants: paint stripping is no longer a marginal production phase.
When properly engineered, immersion paint stripping becomes an integrated process capable of improving coating quality, extending tooling lifespan and ensuring operational continuity. In this specific application, FASTRIP T6 demonstrated its ability to handle medium-large components under real production conditions while maintaining stable performance day after day. More than a simple stripping tank, the system operates as a complete industrial ecosystem designed to deliver control, efficiency and operational continuity on an industrial scale.
