Case Study: Overhead Chain & Vertical Conveyors in a Paint & Finishing Line
How a manufacturer freed floor space, improved coating consistency, and simplified flow using GlobalRoll Overhead Chain and Spiral & Vertical Conveyor Systems.
A manufacturer of metal components needed a better way to move parts through wash, paint, cure, and final assembly without clogging the floor with work-in-process. GlobalRoll supplied an Overhead Chain Conveyor System and a Spiral & Vertical Conveyor System that together created a continuous, overhead flow from prep to assembly—improving quality, space utilization, and throughput.
Key Highlights:
- Created continuous, overhead flow for painted parts
- Freed up floor space previously consumed by carts and racks
- Improved coating consistency and cure times
- Simplified downstream part delivery to assembly
About the Operation
The customer manufactures metal components that require multi-step surface preparation and painting. The process includes wash, dry, primer, topcoat, curing, inspection, and final assembly. Previously, parts moved in batches on carts and racks, consuming floor space and making it hard to track WIP.
The Problems They Needed to Solve
Congested Floor Space
Parts in various stages of finishing occupied a large portion of the floor on carts and racks, making it difficult to move personnel and materials safely.
Inconsistent Coating and Cure
Because parts moved in batches and waited at each stage, dwell times in wash, paint, and cure were inconsistent—impacting coating quality.
WIP Visibility
It was difficult to know how much work was in each stage and where specific jobs were in the process.
Disconnected Finishing and Assembly
Finished parts often arrived at assembly in irregular batches, causing stops, starts, and micro-scheduling issues.
Overhead Chain + Spiral & Vertical Conveyors
Overhead Chain Conveyor System
GlobalRoll designed an Overhead Chain Conveyor System to carry parts through wash, paint booths, and curing ovens. Custom carriers and brackets were engineered to hold each part securely and in the correct orientation for coating. The overhead path ran above the floor, freeing space and creating a clear visual of where parts were in the process.
Spiral & Vertical Conveyor System
Downstream from curing, a Spiral & Vertical Conveyor System lowered finished parts from the overhead path to the assembly level. This allowed painted parts to arrive at assembly in a controlled, continuous stream rather than sporadic batches.
Integrated Flow and Timing
Line speed and conveyor layout were set to provide correct dwell times in wash, paint, and cure zones. Buffer areas were built into the overhead path to accommodate process variation without backing up workstations.
Implementation & Line Conversion
The project was implemented in stages:
Phase 1 – Modeling and Simulation
The existing batch process was mapped and modeled, and the new overhead path was designed to ensure required dwell times and clearances.
Phase 2 – Structural & Mechanical Install
Support steel, track, carriers, drives, and spiral/vertical equipment were installed, initially run in parallel with the old process for testing.
Phase 3 – Transition to Continuous Flow
Parts were gradually moved from the old cart/rack method onto the overhead system. Operators and quality staff were trained on the new flows and inspection points.
Results: More Space, Better Flow, Better Finish
Floor Space Freed
Removing carts and racks from the main production area opened up aisles and work zones, improving safety and flexibility.
Consistent Coating and Cure
Continuous overhead movement with controlled line speed provided consistent dwell times in wash, paint, and curing zones, resulting in more uniform finishes.
Improved WIP Visibility
With product visibly moving overhead, managers and operators could see where work was in the process at a glance.
Smoother Feed to Assembly
The Spiral & Vertical Conveyor System delivered finished parts to assembly steadily, reducing stop/start behavior and improving line balance.
Systems Used in This Project
- Overhead Chain Conveyor System – Carried parts overhead through wash, paint, and cure with custom carriers.
- Spiral & Vertical Conveyor System – Brought finished parts from overhead down to assembly level in a controlled, space-efficient way.
Planning a Paint or Finishing Line?
If your finishing or paint area is crowded with carts and racks—or if you’re struggling with inconsistent dwell times and WIP visibility—an overhead and vertical conveyor strategy can help. GlobalRoll can work with your team to design a continuous-flow solution built on proven overhead chain and spiral/vertical product families.