Bespoke Spraybooth Installation for Penske Porsche, Germany
A challenging first-floor installation for Penske Porsche in Germany, featuring a fully electric Cyclone spraybooth designed around a low ceiling and complex existing services.
Double hangar installation Lithuania
A large-scale aircraft hangar paint facility designed to accommodate A320 and B737 aircraft, featuring high-capacity airflow, heating, and humidification systems to maintain consistent conditions for precision spraying.
Project overview
This project involved the delivery of a purpose-built paint facility within a double narrow-body aircraft hangar, designed to accommodate aircraft such as the Airbus A320 and Boeing 737.
Located outside the UK, the facility was developed to support large-scale aircraft spraying operations, requiring a high-performance environment capable of maintaining consistent conditions across a significant internal volume. STL was responsible for the design and integration of the spray environment systems, forming a critical part of the hangar’s overall functionality.
The challenge
The scale of the hangar presented a key challenge, with a total internal volume exceeding 21,000 m³. The system needed to deliver consistent airflow across the entire spraying area while maintaining stable temperature and humidity conditions suitable for high-quality aircraft finishing.
As an international project, additional coordination was required to ensure the system aligned with local requirements while maintaining STL’s performance standards. Achieving the correct balance between airflow, heating, and humidification within such a large space was critical to the success of the facility.
The solution
We delivered a high-capacity spray environment system designed specifically for large aircraft applications.
The installation was engineered to achieve an airflow rate of 175,000 m³/h across the spraying area, ensuring effective air movement and consistent operating conditions throughout the hangar.
To support environmental control, the system included:
- Two 500kW direct-fired gas burners, capable of achieving hangar temperatures of up to 40°C
- Two 240kW humidification units, maintaining relative humidity levels between 40% and 70%
This combination of airflow, heating, and humidification ensured the facility could operate reliably across a range of conditions, supporting both performance and finish quality.
The result
The completed facility provides a controlled, high-performance environment for aircraft spraying, capable of supporting consistent results across large airframes.
The combination of scale, environmental control, and international delivery reinforces our capability in delivering advanced solutions for the global aviation sector.
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