Technology for large-format components

Modular System – Doubling critical infrastructure production

Client profile: Leader in European modular construction

Modular System is one of the largest producers of advanced container systems in Europe. The company specialises in providing professional and safe modular systems used in critical infrastructure, the humanitarian sector, and in situations of natural disasters and armed conflicts. Their solutions reach customers throughout Europe and the United States, requiring compliance with the highest global durability standards.

Strategic goals: Doubling production and process automation

The dynamic growth in demand for modular systems forced the company to radically expand its production capacity while simultaneously reducing manual labour.

Key performance indicators (KPIs) for the investment:

Production scale: Achieving a capacity of over 300 containers per day.
Anti-corrosion precision: Ensuring complete protection for hard-to-reach areas of steel structures.
Bulk management: Handling of items weighing up to 600 kg and up to 6 metres long.
Energy optimisation: Heat recovery from massive components to protect the hall’s microclimate.

Challenge: Giant scale in a confined space

Głównym wyzwaniem projektowym była konieczność zintegrowania wielkogabarytowej linii lakierniczej w ograniczonej kubaturze hali. Linia musiała pracować w trybie ciągłym z prędkością 1,5 m/min, co nie wybacza najmniejszych przestojów.

The specific nature of the parts posed an additional challenge – the semi-closed container frames required flawless surface preparation and paint application in extremely difficult-to-access nooks and crannies. The project required perfect coordination of many subcontractors led by Ecoline.

Ecoline solution: Intelligent Painting Ecosystem 4.0

Ecoline has designed a line that is “one organism,” where each technology is tightly integrated with the data exchange system.

1. Hybrid surface preparation

An innovative shot-blasting system was used. To clean hard-to-reach areas, a novel continuous pneumatic shot-blasting process was implemented, eliminating the problem of abrasive residue and ensuring perfect coating adhesion.

2. Large-scale booth with dense-phase pump technology

To ensure full coverage of 6-metre-long workpieces, Ecoline implemented a 6-metre-high booth equipped with 24 guns based on dense-phase pump technology. The system is fed by large “big bag” tanks, ensuring continuous paint delivery with a high mass flow rate.

3. Advanced polymerisation and 70% energy recovery

The 5-metre-high furnace with a power output of 550,000 kcal handles a batch weight of 180–200 tons per day. A key innovation is the cooling tunnel, which recovers over 70% of the thermal energy from the parts, using it to heat the hall in winter.

4. Data integration and Artificial Intelligence

The Ecoline data exchange system integrates Modular System production orders with the operation of the Power & Free conveyor and all line components. AI algorithms analyse process data, predicting failures and optimising bottlenecks in real time.

Measurable investment results

Doubling production capacity:

The line enables faster and larger deliveries, strengthening the company’s position in the global market.

Maximum coating durability:

Thanks to the flawless shot-blasting and painting process, Modular System products meet the requirements of the most demanding environments (military, humanitarian missions).

Massive energy recovery:

Over 70% of the energy from heated parts remains in the process, drastically reducing operating costs and improving work comfort in the hall.

Full traceability:

Każdy detal posiada cyfrowy raport malowania, co pozwala na pełną kontrolę jakościową wstecz za pomocą kodów QR.

“The comprehensive coordination of the installation, managed by Ecoline, played a key role. With such complex projects, not only the best technology is important, but also coordination skills and efficient problem-solving. Thanks to this investment, we are ready to meet the growing demands of the critical infrastructure market.”

Modular System Management

Summary: Industrial symphony of modernity

The Modular System project demonstrates that automation and robotics are the only way forward for companies operating on a large scale. Thanks to the synergy of Ecoline technology and close collaboration with subcontractors, a line was created that not only doubled production but also became a benchmark for energy and process efficiency in the modular systems industry.