Inokom has expanded their Kulim plant with a new advanced paint shop.
Inokom Corporation Sdn Bhd, a subsidiary of Sime Darby Berhad under its Sime Motors division, has officially launched its new vehicle painting facility, Paint Shop 3 (PS3), at its 200-acre assembly complex in Kulim, Kedah.
Officiated by Minister of Investment, Trade and Industry Datuk Seri Johari Abdul Ghani, the facility represents an investment of approximately RM300 million, making it one of Sime’s largest manufacturing commitments to date. Constructed and operated entirely by a local Malaysian workforce, the expansion strengthens Inokom’s position as a contract manufacturing hub for global and regional automotive brands.
Doubled Annual Capacity and Production Flexibility
Operating on a two-shift system, PS3 is engineered to support up to 50,000 painted vehicle bodies per year at a output rate of 15 units per hour, alongside dedicated plastic parts painting capabilities.
The addition of PS3 effectively doubles Inokom’s total combined paint shop capacity to 100,000 vehicle bodies per annum. The facility is built to support multiple vehicle models and multi-brand assembly requirements simultaneously, providing regional OEMs with scaled flexibility for future local assembly (CKD) programs.
Robotic Automation and Technical Collaboration With Mazda
Operations within PS3 feature a high degree of automation, anchored by a fully automated pre-treatment and electrodeposition (PTED) line, advanced spray booths, and an integrated conveyor network spanning 1,053 meters.
- Robotic Precision: Outfitted with 32 painting and sealant robots designed for uniform application across exterior panels, interior structures, and plastic trim.
- Rapid Color Switching: Integrates a Cartridge Bell System (CBS) capable of executing color changes in under 10 seconds across up to 27 color options, drastically cutting operational downtime.
- Streamlined Inter-Shop Logistics: Vehicle bodies move between the Body Shop, PS3, and Assembly Shop via overhead transfer tunnels, minimizing manual handling and environmental contamination.
- Three-Coat, One-Bake Process: Applies three coating layers within a single oven baking cycle, significantly reducing thermal processing time and energy consumption.
Development and commissioning of the facility were supported by close technical collaboration with Mazda’s engineering team, facilitating technology and knowledge transfer to Inokom’s local engineering staff.
Environmental Sustainability Features
PS3 incorporates several sustainable manufacturing systems to reduce its carbon footprint and environmental impact:
- Emissions Reduction: A Regenerative Thermal Oxidiser (RTO) connected to four process ovens decomposes volatile organic compounds (VOCs) and recycles recovered heat, reducing carbon dioxide emissions by approximately 60 percent.
- Waterless Spray Booths: A dry scrubber filtration system eliminates water usage during spray booth operations, reducing industrial wastewater treatment needs.
- Waterborne Paint Readiness: Fully pre-configured to transition smoothly to waterborne paint formulations as OEM environmental regulations evolve.
- Smart Thermal Layout: Production lines are positioned at ground level while baking ovens are located on the upper floor, reducing heat exposure in worker areas and lowering ambient cooling energy demand.
