Revamping Efficiency: How Rowley Projects Helped Truckman Transform Their Painting Operations

The Challenge: Bringing Efficiency In-House

Imagine running a fast-paced manufacturing operation where efficiency and quality are critical, but your key processes are outsourced. That was the reality for Truckman, a leading automotive manufacturer based in Dudley.

Their goal was clear:

• Gain full control over painting quality and efficiency.
• Optimise warehouse space to accommodate a bespoke spray booth.
• Build a scalable setup to future-proof their growing business.

But as with any significant upgrade, challenges loomed large.

Navigating Tight Spaces and Tall Orders

The space available for the spray booth was incredibly confined—wedged into a corner of the warehouse with looming mezzanine columns and low ceilings. Adding to the complexity, existing ducting needed repositioning for optimal airflow.

And then there was the deadline. Truckman needed the entire project completed in just five weeks. It seemed almost impossible, but Rowley Projects thrives on challenges.

A Tailored Solution: Engineering for Success

To meet Truckman’s unique requirements, Rowley Projects didn’t just deliver a spray booth—they engineered a complete transformation. The solution? A bespoke 9m x 4m Maxi Spec booth.

This custom-built booth was designed to fit the awkward space while addressing height and ducting limitations. The result was a high-spec, user-friendly setup optimised for current and future demands.

But Rowley didn’t stop there. Understanding the need for scalability, they built the booth to handle up to three jobs at once, boosting productivity and allowing Truckman to complete up to 12 jobs per day.

The final product featured:

• Raised Floor Extraction: Enhanced airflow for better performance.
• LED Lighting: Energy-efficient and perfect for visibility.
• Push-Button Controls: Simplifying the spray, flash-off, and bake processes.

Morelli Group played a key role in sourcing technical elements and providing ongoing support, ensuring Truckman’s new setup would remain reliable and efficient for years to come.

A Game-Changer for Truckman

When the dust settled, the results were undeniable. Truckman had successfully brought their painting operations in-house, significantly boosting efficiency and reducing bottlenecks.

As Brett Hall, Operations Manager at Truckman UK, put it:

“The Raised Floor Maxi Spec Booth has not only given us the ability to paint up to three hardtops simultaneously but also future-proofed our operations. With improved efficiency yielding up to 12 completed jobs per day, we can now meet growing demand consistently and reliably.”

Brett also highlighted the energy savings brought by the LED lighting, which not only reduced consumption but also improved visibility and finish quality.

Looking Ahead: A Partnership for the Future

By partnering with Rowley Projects, Truckman gained more than just a spray booth. They secured a solution designed to adapt and grow with their business. The bespoke design has empowered them to increase output, streamline processes, and reclaim control over their operations.

The journey from planning to installation was completed in just five weeks, including a rapid three-week turnaround for delivery. The collaboration didn’t just meet expectations—it exceeded them.

Rowley Projects continues to support Truckman as they build on this success, proving that the right partnership can make all the difference.

Thinking of Upgrading Your Workshop?

If your business is looking to optimise its operations, consider partnering with Rowley Projects. With bespoke solutions tailored to your unique challenges, Rowley is dedicated to helping workshops and manufacturers reach new levels of efficiency.