Industrial disperser for increasing production capacity
Challenge: Increase production capacity without expanding facilities, working with variable batches of varnishes and water-based and solvent-based paints.
Solution: Polimix DPS-5000-TRC ATEX disperser.
Result: Significant increase in production capacity, greater operational flexibility, and reduction in manual operator intervention.
1. IRURENA GROUP
IRURENA Group is a family-owned industrial company founded in 1969, specialized in the manufacture of varnishes and paints for industrial applications, mainly on wood, in both water-based and solvent-based formulations.
2. Products and Manufacturing Challenges
- Water-based paints for industrial applications on wood
- Solvent-based paints with ATEX requirementsTechnical complexity: The variability of formulations and production volumes required a dispersion system capable of adapting to different products while maintaining process quality and production efficiency.
- Industrial varnishes for high-quality professional finishes on wood
Technical complexity: The variability of formulations and production volumes required a dispersion system capable of adapting to different products while maintaining process quality and production efficiency.
3. Project Objectives
Main objective: Increase the production capacity of the existing plant by incorporating new dispersion equipment capable of working with both small and large batches, without the need to expand facilities or modify the manufacturing platform.
| Challenge | Description |
| Space | Integration of equipment in a reduced space, within an already operational production facility. |
| Coordination | Technical coordination with different project contractors, ensuring proper integration with auxiliary systems for liquid and solid feeding, dust and vapor extraction, cleaning solvents, complying with ATEX requirements. |
| Installation | Execution of complex maneuvers, conditioned by equipment dimensions and plant access limitations. |
Critical requirement: The entire project had to guarantee safe, reliable operation oriented toward optimizing daily operations.
4. Implemented Solution
Polimix DPS-5000-TRC ATEX Equipment
Oliver + Batlle designed and manufactured a high-power disperser specifically configured for the client’s production needs, ensuring maximum efficiency and operational safety.
Main Technical Features
- Truncated-conical design: Allows efficient work with both small and large product volumes
- Disperser shaft raising and lowering system: Provides flexibility and control during the manufacturing process
- Half-pipe cooling jacket: Ensures thermal stability of the product during dispersion
- Automatic cleaning system: Using mobile lances, with integrated process control
- Complete control of the equipment: HMI touchscreen in classified zone, while PLC and electrical cabinet are located in safe area, fully compliant with ATEX requirements.
The equipment was installed on a carbon steel support structure with primer coating, designed at the same height as the existing production platform. Oliver + Batlle provided the loads transmitted to the floor so that the client could execute the corresponding foundations, as well as the anchor plates on which the structure and the equipment rest. The position of the liquid and powder loading connections and the vapour/dust extraction points was also defined.
A specialized technician from Oliver + Batlle coordinated the positioning operations, final assembly, and commissioning of the equipment, ensuring its proper integration into the plant.
Process diagram of supplied equipment:
3D views of the equipment on its structure, integrated in the existing factory:
5. Results
- Significant increase in the production capacity of the existing plant without the need to expand facilities
- Maximum operational flexibility: production of large and small batches of a wide variety of products using a single disperser
- Improved efficiency of the production process through integrated automatic control
- Reduced operator intervention: manual and automatic operation, and integrated cleaning system
6. Conclusion
This project demonstrates how a customized engineering solution, properly integrated into an existing installation, optimizes production and prepares the plant for future growth.
The combination of specialized technical design, ATEX regulatory compliance, integration within reduced space, and process automation has enabled IRURENA GROUP to strengthen its competitive position in the industrial coatings market.
