Featured Engineered to Order Power Generation Solutions
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A global leader in wind turbine manufacturing required a massive, precision-engineered blast room to prepare composite and hybrid turbine blades—often exceeding 80 meters (260 feet) in length—prior to final coating, bonding, or structural assembly. These surfaces must be free from mold release agents, oxidation, and surface irregularities to ensure optimal paint adhesion, aerodynamic efficiency, and structural integrity in harsh operating environments. The solution needed to accommodate ultra-large components, deliver uniform and repeatable surface prep, and support sustainability and throughput targets in a clean energy production facility.
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Clemco collaborated with the turbine manufacturer’s engineering, quality, and sustainability teams to co-develop a fully automated blast room system tailored to the scale and sensitivity of wind blade manufacturing. The design process included:
Mapping blade geometries to develop multi-axis blast nozzle gantry systems for full coverage across curved and tapered surfaces
Selecting non-abrasive or lightweight blasting media (e.g., glass bead or plastic media) appropriate for composite surfaces and internal structural features
Engineering a climate-controlled enclosure with advanced airflow and dust extraction to protect surface cleanliness and maintain operator safety
Developing intelligent automation controls with programmable recipes for different blade designs and surface specifications
Ensuring the system aligned with lean manufacturing principles and sustainability goals, including abrasive recycling and energy efficiency
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Clemco delivered a monumental-scale, fully automated blast room capable of preparing utility-grade wind turbine blades, featuring:
A custom-built blast chamber large enough to house full-length blades with rail-mounted blast nozzle gantries and part-handling fixtures
Advanced HMI/PLC controls for managing blast cycles, media flow, and operator safety zones
Non-destructive media delivery systems that provide even, gentle coverage without compromising laminate integrity
Multi-stage dust collection and recovery systems for clean operation, low media waste, and regulatory compliance
Full documentation, technician training, and startup support to ensure reliable operation and minimal downtime
The result was a high-precision, high-throughput blast solution that enabled the wind turbine manufacturer to improve blade coating performance, structural consistency, and aerodynamic efficiency—accelerating production while supporting global clean energy goals.
Wind Turbine Blades
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A global power transformer manufacturer needed a large-scale, automated blast room to support maintenance, repair, and overhaul (MRO) of main transformer tanks and radiator assemblies. These components—often exposed to years of weathering, oil contamination, and corrosion—required complete removal of coatings, rust, and debris to prepare them for repainting, relining, or requalification. The solution needed to support heavy steel structures, enable precise and consistent surface prep, and ensure full compliance with electrical utility and environmental standards.
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Clemco collaborated with the customer’s MRO, engineering, and EHS teams to design a fully automated blast room capable of handling large, heavy, and uniquely shaped transformer components. The design process focused on:
Accommodating both vertical and horizontal blasting orientations for tall tanks and extended radiator arrays
Designing multi-axis automated blast nozzle gantries to provide uniform coverage over flat, curved, and finned surfaces
Selecting abrasive media suited for heavy steel cleaning without distorting radiators or damaging weld seams
Engineering the room for overhead crane access, walk-in service bays, and high-efficiency media reclaim systems
Integrating ventilation, dust collection, and filtration systems to meet air quality and operator safety standards
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Clemco delivered a massive, turnkey automated blast room system optimized for transformer tank and radiator MRO, featuring:
A reinforced steel blast enclosure with high-lumen lighting, noise suppression, and safety interlocks
Automated blast nozzle gantries with programmable controls to ensure repeatable surface profiles across complex geometries
A rugged abrasive recovery system with classifiers and media recyclers to maintain blast efficiency and reduce operating costs
Integrated dust collection and air quality control, maintaining visibility and OSHA compliance
Full training, documentation, and support to ensure smooth commissioning, long-term reliability, and minimal downtime
The result was a high-capacity, precision-engineered blasting solution that empowered the transformer manufacturer to restore core components to OEM-quality standards, extend equipment life, and support critical grid infrastructure across global markets.
Transformer MRO
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A leading global solar panel manufacturer needed a large-scale, automated blast room to prepare metal support structures, panel frames, and mounting assemblies for final assembly and coating. These components—typically made from aluminum and galvanized steel—required a uniform, contaminant-free surface profile to ensure long-term durability, optimal coating adhesion, and resistance to environmental degradation. The blasting process had to be highly controlled, cleanroom-adjacent in quality, and capable of high-volume throughput to match the company's global production scale.
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Clemco partnered with the manufacturer’s production engineering, materials, and sustainability teams to develop a precision-engineered automated blast room tailored to the unique requirements of solar energy hardware preparation. Key elements of the design process included:
Identifying the ideal abrasive media and pressure levels for aluminum and coated steel components
Designing automated gantry-mounted blast nozzles to cover large surfaces efficiently and without distortion
Engineering the room to support modular fixtures for varying frame sizes and lightweight part handling
Ensuring compliance with ISO 9001, ISO 14001, and other industry-specific environmental and quality standards
Integrating media reclaim systems and dust filtration to support clean, sustainable operations and limit airborne particulates
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Clemco delivered a high-throughput, fully automated blast room optimized for solar panel unit preparation, featuring:
A spacious blast chamber with programmable, multi-axis blast gantries capable of preparing both large panel frames and small subassemblies
Touchscreen HMI controls for recipe-driven operations based on material type and component geometry
Media recovery and separation systems to maintain abrasive consistency and minimize waste
Advanced dust collection, air filtration, and lighting systems to ensure visibility, part quality, and workplace safety
Operator training, startup support, and process documentation to ensure compliance, efficiency, and continuous improvement
The result was a scalable, clean-energy-ready blast room that enabled the manufacturer to enhance product quality, coating durability, and assembly line reliability—all while supporting sustainability objectives and global deployment of renewable energy infrastructure.
Solar Panel Preparation
Power Generation Solutions
Proven Performance. Rugged Reliability.
Generations of Excellence Transforming Our World, Worldwide since 1941
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Generations of Excellence Transforming Our World, Worldwide since 1941
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Generations of Excellence Transforming Our World, Worldwide since 1941
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Generations of Excellence Transforming Our World, Worldwide since 1941 • Generations of Excellence Transforming Our World, Worldwide since 1941 • Generations of Excellence Transforming Our World, Worldwide since 1941 •
