Increased production with full chemical risk control

Semi-automated chemical application booth for denim garments

Context and identified problem:

In the finishing area of a textile plant, the painting process for jeans was performed manually in an open space, creating risks of chemical exposure, lack of uniformity in the finish, and low production efficiency. The operation lacked an extraction, filtration, and environmental control system, failing to comply with industrial safety and current environmental standards.

Implemented solution:

A fully enclosed paint booth was designed and built, featuring a metal structure, insulation, and a controlled ventilation system. The system included mannequin inflation managed by PLC and a semi-automated chemical spraying process, with supervised operator intervention to ensure precision. The booth integrates industrial lighting according to regulations, extraction hoods, and a cascade system to neutralize and filter potassium permanganate before disposal.

Results achieved:

- Increased capacity: from 16 to 20 mannequins operating simultaneously.
- 5% reduction in work time per garment.
- Elimination of chemical exposure for personnel.
- Compliance with lighting, ventilation, and environmental control standards.
- Uniform quality control in garment finishing.

Coordination and execution:

The project was carried out in coordination with the plant’s production, industrial safety, and maintenance departments, optimizing the design to fit the available space and production sequence. Implementation was completed without disrupting operations, ensuring a smooth transition to the new system.