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2026Car Wash Tunnel Revamping: Efficiency and Customization
Eurotherm designed and carried out a major revamping project on an existing washing tunnel at the Turin plant of a leading industrial group in the automotive sector. This solution was developed for customers who need to upgrade the pretreatment section, optimize fluid management, and improve vapor extraction without replacing the entire system.
The Challenge: Integration into Existing Spaces and Operational Continuity
The customer had a clear and specific need: to modernize and upgrade the industrial washing and degreasing system currently in use, adapting the new components to the strict dimensional constraints of the existing line and the available space in the plant. Traditionally, replacing process tanks in complex plants requires structural modifications or invasive changes to the production layout. The challenge for the Eurotherm team was to engineer and build two heating tanks, each with a capacity of 7,000 liters, custom-designed to integrate seamlessly into the existing structure and ensure high filtration and heating performance.
The Eurotherm Solution: Custom Engineering for Surface Treatment
To address this need, we carried out a targeted revamp of the wash tunnel, installing new insulated stainless-steel tanks and integrating a dedicated vapor extraction system in the final blow-dry area.
Technical Specifications of the Project
- Custom Heating Tanks: 2 new tanks for degreasing liquids, each with a capacity of 7,000 liters, made of stainless steel, insulated, and designed with custom shapes and dimensions to fit the space available in the existing facility.
- Gas heating system: Each tub is equipped with a gas heating system to quickly reach and maintain the operating temperature of the baths.
- Liquid recirculation: Each tank is equipped with a recirculation pump for filtering the liquids and a pump for delivering the liquid to the tunnel nozzles.
- Two-stage filtration: a recirculating liquid filtration system with in-line stainless steel baskets, designed to trap impurities and maintain the cleanliness of degreasing solutions.
- Vapor Extraction and Filtration: Installation of a new vapor extraction and filtration system in the final blow-off area, designed to prevent the dispersion of mists into the workplace.
Get in touch
Do you have a washing or pretreatment system that needs to be modernized? Contact our specialists to design a customized revamping project.
Revamping, Efficiency, and Sustainability
The concept behind this project can be summarized in three key areas: performance restoration, energy efficiency, and operational safety. Thanks to its custom design, the revamp extends the service life of the company’s car wash tunnel, avoiding the costs and time associated with a complete replacement.
High performance and fluid cleanliness: the integrated component architecture is designed to optimize production output.
- Continuous filtration: The two-stage inline stainless-steel basket filter retains solid residues and sludge, reducing the frequency with which degreasing baths need to be replaced.
- Minimizing Heat Loss: Insulating the stainless steel tanks reduces heat loss, thereby optimizing gas heating consumption.
- Protection of the production environment: The exhaust system in the final blowing zone captures residual vapors before the parts exit the tunnel.
Why Choose Eurotherm for Plant Revamping
This project demonstrates how custom-designed systems can overcome the space constraints of existing facilities while maintaining high standards of finish quality, operational continuity, and safety.
Revamping is an effective solution for:
- Industrial facilities with fixed layouts where standard machinery cannot be installed.
- Companies that aim to reduce fuel consumption for heating degreasing solutions.
- Facilities that require an efficient vapor collection and filtration system during the blow molding process.
The integration of custom-made stainless steel tanks and the vapor extraction system results in a modernized, high-performance washing area. From an operational standpoint, the system is designed to ensure stable process parameters, with particular attention to:
- Thermal efficiency of degreasing tanks
- filtration efficiency of recirculating liquids
- Vapor capture efficiency in the final zone
- reduction in maintenance work
These factors are crucial for maintaining consistent treatment quality and reducing operating costs over time.
Get in touch
Upgrading an existing system is a strategic choice for increasing efficiency while reducing downtime and costs. Eurotherm is the ideal partner for the design and integration of custom components into industrial car wash tunnels. Talk to our specialists to identify the revamping solution that best suits your needs.