Hybrid regenerative spraybooths

STL was appointed to develop and deliver an advanced spraybooth solution for a high-end automotive facility seeking the latest technology while significantly reducing carbon footprint and energy consumption. The customer required a regenerative system that maximised energy efficiency without compromising finishing performance, process times, or throughput.

Following detailed technical analysis, STL engineered and supplied two latest-generation hybrid spraybooths, combining regenerative air-to-air heat recovery with a hybrid gas and electric heating strategy.

The project required next-generation spraybooths aligned with strict sustainability and carbon reduction objectives.

Key requirements included:

• Substantial reduction in gas usage compared to conventional spraybooths

• Faster drying cycles and higher effective panel temperatures

• Consistent, high-quality finishes with reduced operational costs

• Long-term energy efficiency without increasing complexity

STL engineers developed a Hybrid Spraybooth system featuring a regenerative air-to-air heat recovery unit, reducing heat losses throughout operation. The system combines a fully modulating gas burner with targeted electrical heating through dual rows of Aquadry nozzles.

This hybrid approach allows the spraybooths to operate with lower gas demand while delivering heat precisely where it provides the greatest performance benefit. By increasing nozzle discharge temperatures rather than overall cabin temperatures, the system achieves faster, more efficient heat transfer to vehicle panels.

The regenerative design further reduces energy demand by reusing heat from process air, ensuring consistent operating conditions and reduced energy input across all spraybooth phases.

• Regenerative air-to-air heat recovery for maximised energy reuse

• Hybrid heating with modulating gas burner and targeted electric heating

• Dual-row Aquadry nozzle system for faster panel temperature rise

• Significantly reduced gas consumption

• Lower cabin temperatures with improved heat transfer efficiency

• Reduced cool-down times and shorter overall process cycles

• Increased workshop throughput and productivity

The installed hybrid spraybooths deliver a step-change in both energy efficiency and spraybooth performance. Gas consumption per process is greatly reduced, and electrical energy demand is optimised through regenerative heat recovery.

Performance is enhanced with faster panel temperature rise, higher effective panel temperatures, and shorter overall process cycles. These improvements translate directly into increased productivity and more consistent finishing quality.

A future-focused spraybooth solution that reduces environmental impact, improves operational performance, and lowers running costs. The hybrid regenerative design achieves over 50% reduction in energy usage per process compared to conventional spraybooths.

By combining sustainability with enhanced throughput and performance, the hybrid spraybooth system provides a robust, cost-efficient, and environmentally responsible solution aligned with long-term operational and carbon reduction goals.