Integrated Control System: Intelligent Scheduling & On-Demand Distribution

May 7, 2026, Dongguan – Energy consumption in spray painting workshops has long been a heavy burden for manufacturing enterprises. Paint spray booths require large volumes of fresh air supply to maintain constant temperature and humidity, while curing ovens are notorious "energy hogs". Statistics show that the spray painting process accounts for 15%–25% of a factory’s total energy use, with most heat directly discharged into the atmosphere as exhaust gas, causing massive energy waste and carbon emissions. Dongguan Mansheng Automation Equipment Co., Ltd. has officially launched its Spray Painting Waste Heat Recovery System, which achieves cascade recovery and reuse of waste heat from spray booth exhaust, curing oven residual heat, and air compressors. The system cuts the comprehensive energy consumption of spray booths by more than 35%, with a typical payback period of 1–2 years. The technology has been applied to coating lines of leading enterprises including BYD and Midea, with each system reducing approximately 80 tons of CO₂ emissions annually in actual operation.

The energy flow of a standard automatic spray painting production line (spray booth + curing oven) is as follows:

• To ensure operational safety and coating quality, paint spray booths draw in large amounts of fresh air (20–30 air changes per hour) and discharge exhaust containing paint mist and solvents after treatment. Heating or cooling fresh air to maintain a constant booth temperature (20–25°C) accounts for over 60% of total booth energy use.
• Curing ovens for coating drying operate at 60–180°C, consuming enormous energy via hot air or infrared heating.
• Air compressors supplying air to spray guns and pneumatic components convert about 80% of electrical energy into heat, dissipated unused in compressor rooms.

“Many enterprises only focus on buying more energy-saving spraying equipment, yet ignore the massive heat already being wasted," said a Mansheng Automation energy engineer. “Waste heat recovery is one of the most cost-effective energy-saving measures."

The system is not a single device but a combined solution designed for different heat sources and temperature zones. Customers can select configurations based on workshop conditions and budget.

Although spray booth exhaust contains trace VOCs, it maintains stable temperatures (20–25°C in winter, 30–35°C in summer). Mansheng uses plate sensible heat exchangers or heat pipe exchangers to transfer exhaust heat to incoming fresh air, preheating/precooling it to reduce HVAC loads.

• Winter: Exhaust heat preheats fresh air from 0°C to 15–18°C, cutting heating energy use by ~50%.
• Summer: Exhaust temperature is lower than outdoor high temperature, precooling fresh air to reduce cooling load.

This module achieves 65%–70% heat exchange efficiency, with a payback period of about 1.5 years. The effect is especially significant in northern regions.

Curing oven exhaust features high temperature and large heat value. Mansheng deploys gas-to-gas plate heat exchangers or hot air circulation bypasses to reuse exhaust heat for preheating fresh air or return air entering the oven. Case Study: An auto parts plant operated its curing oven at 150°C with exhaust at 130°C. After installing a Mansheng high-temperature heat exchanger, fresh air was preheated from 20°C to 95°C, reducing natural gas consumption by 38%, saving ¥220,000 in fuel costs annually, with equipment investment recovered in 11 months. Additionally, Mansheng can redirect oven waste heat for winter workshop heating and hot water production for multi-purpose utilization.

During operation, air compressor lubricating oil and compressed air reach 70–90°C. Mansheng installs plate-shell oil-water exchangers or gas-water exchangers to transfer this heat to water circulation systems, producing 60–70°C hot water. The hot water can be used for:

• Winter spray booth makeup air heating (via hot water coils)
• Preheating workpieces before painting (to eliminate surface condensation)
• Hot water supply for cleaning lines
• Staff bathrooms and canteen hot water

A 55kW air compressor at full load generates waste heat equivalent to a 25kW electric heater, with annual recovered heat worth ~¥80,000–100,000 in electricity costs.

The Mansheng waste heat recovery system is not a single device but is centrally managed by a central energy efficiency controller. The controller monitors real-time temperature, flow, and equipment status at each stage, automatically allocating heat sources:

• Prioritize curing oven waste heat for fresh air heating or workpiece drying
• Supplement with air compressor waste heat when oven heat is insufficient
• Switch excess heat to workshop heating or hot water production
• Disable partial recovery loops in summer to avoid overheating

“We integrate waste heat recovery into the overall control logic of the spray line, rather than treating it as a standalone add-on," said a Mansheng electrical engineer. “For example, during color change and cleaning, when spray booth exhaust volume drops, the system automatically adjusts recovery ratios to maximize energy savings."

A home appliance coating plant in Foshan, Guangdong operates 2 automatic spray lines (Mansheng 6th-generation equipment), with annual electricity use of ~2.1 million kWh and natural gas use of ~250,000 m³. After installing a full three-stage Mansheng waste heat recovery system in 2024, one-year operational data is as follows:

Payback Period: Total system investment ~¥580,000, recovered in 11 months. Annual CO₂ reduction ~142 tons, with a government energy-saving renovation subsidy of ¥120,000. The plant director stated: “We used to think waste heat recovery was only for large enterprises, but Mansheng made it practical. The ¥650,000 saved each year is pure profit."

The Mansheng waste heat recovery system delivers maximum benefits for:

• Northern regions (long winter heating season, high spray booth heating energy use)
• Curing ovens >120°C (high-temperature paint baking, powder curing)
• Large air compressors (≥50kW installed capacity)
• Year-round continuous operation (24h/3-shift production)
• Facilities with hot water demand (dormitories, cleaning lines)

For small, intermittently operated workshops in southern China, the payback period may be longer. Mansheng engineers provide free assessments for customized recommendations.

As China’s “Dual Carbon" strategy advances, many regions have implemented carbon emission quota management for key energy consumers. Lower energy use from waste heat recovery directly translates to surplus carbon quotas, which can be traded for profit or avoid over-limit fines. Additionally, reducing spray booth exhaust temperature supports stable operation of downstream exhaust treatment equipment (e.g., zeolite rotor + RTO), cutting preheating energy use and creating a superimposed energy-saving effect. Mansheng assists clients in applying for financial incentives for energy-saving technical renovations (typically 10%–20% of equipment investment) and certifications such as Green Factory.

A key challenge for waste heat recovery in spray painting exhaust is paint mist particles clogging heat exchangers. Mansheng has implemented targeted designs:

• Recovery systems installed after the filtration stage of exhaust treatment equipment, removing most paint mist before the exchanger
• Detachable heat exchanger structure for cleaning every 3–6 months to restore efficiency
• Special fin spacing (≥6mm) and self-cleaning angle (15° tilt) to reduce particle adhesion
• Pulse back blowing before exchangers for regular dust removal

“Conventional heat exchangers used in spray exhaust can lose 50% efficiency in three months. Our design ensures performance degradation ≤10% over three years," said a Mansheng product manager.

Note: Typical values; vary by regional energy prices and operating hours.

To lower upfront investment barriers, Mansheng offers three business models:

1. Direct Purchase: Client buys the system outright; Mansheng handles installation and commissioning, with a 2-year warranty.
2. Financial Leasing: Client pays 30% down payment, with the balance in 36 installments; Mansheng subsidizes part of the interest.
3. Energy Performance Contracting (EPC): Mansheng funds and builds the recovery system, sharing 40% of saved energy costs over a 3–5 year contract term. The system is transferred to the client free of charge upon expiration. Suitable for cash-tight enterprises.

“We don’t fear clients not paying upfront; we hate to see heat wasted for nothing," said the head of Mansheng’s Energy Saving Division.

Mansheng is developing an integrated green spray workshop solution: Waste Heat Recovery + Photovoltaic Power + Energy Storage System. Rooftop PV powers spraying equipment, energy storage shifts peak loads, and waste heat recovery cuts thermal energy use. Together, they reduce comprehensive energy costs by over 50%, approaching a “zero-carbon" goal. The first demonstration project has been completed at Mansheng’s No.2 Dongguan production base, with an expected annual power generation of 900,000 kWh. Combined with waste heat recovery, the factory’s overall energy use is 42% lower than the industry average.

Mansheng Automation now offers free spray painting energy audits for manufacturing enterprises nationwide. Engineers conduct 2–3 days of on-site measurements using thermal imagers, flue gas analyzers, and flow meters, delivering a detailed report covering current energy use, waste points, renovation plans, and ROI projections – at no cost to the enterprise. “Many enterprises don’t know how much heat they waste. We use data to guide decisions," said a Mansheng energy engineer. “Even if you don’t buy our system, the report will point you toward energy savings." Over 80 enterprises have already booked free energy audits.

Dongguan Mansheng Automation Equipment Co., Ltd. is a national high-tech enterprise and council member of the China Coating Industry Association, holding 13 invention patents. Its spray painting waste heat recovery system realizes cascade utilization of waste heat from spray booths, curing ovens, and air compressors, reducing comprehensive energy consumption by over 35% with a 1–2 year payback period. Applied by clients including BYD and Midea.

Release Date: May 7, 2026