DANA incorporated
Smart Cooling to Optimize the Microclimate in Paint Booths
Dana Incorporated is a global leader in power transmission and energy management solutions for vehicles and machinery.
Founded in 1904 and headquartered in Maumee, Ohio, Dana operates worldwide with over 36,000 employees in 33 countries, providing cutting-edge technologies for passenger vehicles, commercial vehicles, and off-highway equipment. With several facilities in Italy, the company is committed to enhancing efficiency and sustainability in its production processes.
THE CHALLENGE
At some of its Italian facilities, Dana Group operates high-intensity industrial paint booths within its production process.
Excessive heat inside the booths, particularly during the hottest months, posed several critical issues:
✅ Paint quality – Overly hot and dry air compromised the uniformity of the applied coating.
✅ Operator working conditions – Excessive heat inside the booths reduced comfort and efficiency.
✅ Energy consumption – Traditional cooling systems were expensive and unsustainable.
Paint Booths: Critical Environments Requiring Optimization
Paint booths are controlled industrial environments designed to ensure uniform application of paints and coatings on components and products.
Commonly found in the automotive, metalworking, aerospace, and furniture industries, they require precise climate control due to their specific operational characteristics:
✅ Climate Control – Stable temperature, humidity, and ventilation are essential to prevent finishing defects.
✅ Air Exchange – Extraction and filtration systems remove solvent vapors and airborne particles.
✅ ATEX Zones – Many booths are classified as explosion-risk areas, requiring certified, safe equipment.
✅ Pressurization – Some booths operate under positive pressure to prevent contamination, while others use negative pressure to contain vapors.
✅ Process Segmentation – Booths often include separate spray and drying zones, both requiring optimal climate control.
Inside the booths, temperatures can become critically high since air exchange is typically managed solely through external air intake, which can exceed 30°C on hot summer days. Moreover, workers wear protective gear to safeguard against chemical exposure, further increasing thermal stress.
Evaporative cooling offers an effective solution, capable of lowering temperatures without compromising air quality or increasing energy consumption.
Evaporative cooling offers an effective solution, capable of lowering temperatures without compromising air quality or increasing energy consumption.
The Solution
To address these challenges, Dana Group installed three COLDAIR Series C roof-mounted evaporative coolers—one per paint booth—across three of its Italian facilities.
The COLDAIR units were integrated with the booths’ existing ventilation systems, optimizing airflow, ensuring efficient natural cooling, and improving indoor air quality.
✅ Fan-free integration – COLDAIR units were directly integrated into the existing ventilation system, cooling the incoming air without additional energy costs.
✅ Natural and efficient cooling – The system lowers incoming air temperature by utilizing water evaporation, eliminating the need for refrigerant gases.
✅ Optimal humidity control – Ensuring a more uniform, defect-free paint finish.
✅ Energy cost reduction – Without compressors, energy consumption is significantly lower compared to traditional air conditioning systems.
THE RESULTS
The installation of COLDAIR evaporative coolers delivered immediate and measurable benefits, creating more stable thermal conditions, improved air quality, and zero increase in energy consumption, all without requiring major modifications to existing infrastructure.
✅ Better temperature control – The incoming air is cooler and cleaner, positively impacting paint quality
✅ Energy savings – By leveraging the existing ventilation system, COLDAIR units operate without increasing electricity consumption.
✅ More comfortable work environment – Operators work in better conditions, eliminating the risk of heat stress.
With COLDAIR evaporative cooling, Dana Group has achieved effective, sustainable, and energy-efficient cooling for its paint booths.
This solution enhanced both production quality and worker well-being, demonstrating the effectiveness of Impresind’s sustainable climate control technologies for industrial sectors with specific cooling needs.
Other industrial companies, such as Merlo S.p.A. and Fratelli Folcio Woodworks, have also adopted COLDAIR systems to solve climate control issues in their paint booths.
