Automation for the packaging of high-viscosity technical putty

Optimizing production in the construction sector requires technology capable of handling complex materials. In this article, we analyse how Oliver + Batlle‘s advanced engineering solved the packaging challenges of Saint-Gobain Weber UK, the undisputed leader in industrial mortars and cutting-edge solutions in the United Kingdom.

Brief description of the company

Saint-Gobain Weber Ltd is a multinational subsidiary of the prestigious French group Saint-Gobain. The company stands out for its specialization in solutions for the construction and renovation of buildings, providing everything from industrial mortars and ceramic adhesives to advanced thermal insulation systems for facades and floors. Its commitment to quality has positioned it as a benchmark in new construction and restoration projects.

The challenge: Processing high-viscosity and abrasive products

The project focused on a highly complex technical challenge: the processing and packaging of wet plaster for plasterboard (stucco products).

This technical material has physical properties that make it difficult to handle:

Specific density:25–1.35 kg/dm³.
High viscosity: Between 500 and 3000 poises.
Abrasive nature: Requires superior mechanical robustness to ensure constant flow and accurate dosing without damaging the equipment.

Objective of the “Turnkey” project

The main challenge was to implement a turnkey production line capable of automating a previously manual process, while complying with Saint-Gobain Weber’s demanding standards:

High Performance: Achieve a stable rate of 10 containers of 20 kg (15L) per minute.
Maximum Gravimetric Accuracy: Maintain a variability of less than ±100g per container to drastically reduce raw material waste.
Process Integration: Intelligent connection via a handshake system with two existing 3,000L dispersers in the plant.
Innovation in dosing: Design of ad-hoc nozzles to optimize product distribution, avoiding stains in the closure area and ensuring a clean finish.

The Oliver + Batlle Solution: High-strength engineering

At Oliver+Batlle, we implement a comprehensive solution that complies with IP-54 protection standards and is manufactured with AISI-316 stainless steel in all contact areas to combat abrasion.

A) Feeding and Process Integration

Progressive Cavity Pumping Units: Two 15 kW helical pumping units with NBR stators and chrome-plated AlSi-316L stainless steel rotors, specifically designed for handling abrasive products.
Optimized Distribution: Complete installation of pipes and valves for efficient flow from the production area to the packaging area.

B) Automated Packaging Line

Pailmanager V-Flex Denester: Automatic system with capacity for stacks up to 400 mm in height. It enables fully automated format changeover managed from the HMI, with memory for up to 100 recipes, and incorporates photoelectric safety barriers to ensure operational protection.
OB-130-T Gravimetric filling unit: Dual-head system based on the “2-in-1” concept, optimizing the filling cycle without compromising accuracy.
Mettler Toledo Technology: Use of IND570 weighing terminals, ensuring metrological-grade accuracy and reliability in each dosing cycle.
Peripheral Systems and Traceability: Includes DT-350-S lids dispenser with lid presence detector, lid closing station CR-130 for flat press-on lids with manual adjustment, and a checkweigher with automatic rejection for out-of-tolerance containers.
Comprehensive Service: Full project scope, from P&ID and layout design to technical training of plant personnel.

Results

Thanks to the engineering solution implemented by Oliver + Batlle, Saint-Gobain Weber UK has completely transformed the operational capacity of its plant in Flitwick.

The automated line continuously manages destacking, filling, and closing operations, allowing a sustained production rate of 10 units per minute to be achieved. The use of the OB-130-T Gravimetric Filling Machine allows for interleaved filling, optimizing cycle time without compromising the precision required for high-viscosity products.

This technical approach maximizes the profitability and efficiency of the process:

Cost optimization: The high precision of ±100g, together with the automatic rejection system, eliminates costly overfilling and raw material waste, accelerating return on investment.
Operational agility: Downtime between batches is drastically reduced thanks to the automated format changeover managed via the HMI of the Pailmanager V-Flex.
Reliability and durability: The use of AISI-316 stainless steel and the robustness of the helical pump units ensure a long service life for components despite the abrasive nature of technical putty.

As a result, the overall performance of the installation is improved, ensuring the high efficiency and quality standards required by the Saint-Gobain group for its construction solutions.

Conclusion

The success achieved in this project demonstrates that high viscosity and the abrasive nature of technical materials are not obstacles when the right technology is in place. The satisfaction of Saint-Gobain Weber UK, reflected in the words of Toni Wallis—who highlights that Oliver + Batlle‘s solution has enabled them to meet their highest efficiency standards—is the best endorsement of our engineering expertise.

If your plant is also facing challenges in the packaging of technical products, we invite you to discover how we can help transform your operations.

You can see the complete process in the following video available on our YouTube channel.