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Paint Pilot Plant: A Tailored Engineering Solution for Hempel

What characterises Hempel and its activity in the coatings industry?

Hempel is a multinational manufacturer of paints and coatings headquartered in Denmark, specialising in solutions for industrial, marine and protective coating applications. Its products are designed to provide resistance under demanding environmental conditions.

At its Polinyà facility in Barcelona, Oliver + Batlle developed an equipment solution for a pilot plant dedicated to the development and evaluation of new formulations.

What products are processed in the pilot plant?

The pilot plant is designed to carry out manufacturing trials for the development and definition of new formulations. The equipment must therefore offer the versatility required to work with different formulations and viscosities.

In addition, cleaning between batches is essential to prevent cross-contamination and ensure that residues from one manufacturing run do not affect subsequent trials.

What were the main technical challenges of the project?

The main challenge was to integrate the various process, safety and cleaning functions into a compact piece of equipment: the DISPERMIX VF-4-N industrial disperser.

The limited surface area available on the telescopic lid required a specific configuration that could accommodate all the necessary accessories without compromising their integration or functionality.

The main technical requirements were as follows:

  • ATEX safety: integration of a product-level control system to ensure safe operation of the dispersing disc.
  • Solids addition: incorporation of a loading port with a hopper to facilitate bag emptying.
  • Dust extraction: integration of an extraction connection fitted with an automated valve.
  • Equipment cleaning: incorporation of a cleaning head connected to a pneumatic pumping system.
  • Process lighting: integration of a light to improve visibility during operation.

The equipment also had to handle a wide range of formulations, including high-viscosity paints. Effective cleaning of the disperser and manufacturing vessels at the end of each batch was another key requirement, helping to minimise the risk of cross-contamination.

How did Oliver + Batlle address the pilot plant’s requirements?

Oliver + Batlle developed a specific configuration of the DISPERMIX VF-4-N to make the best possible use of the available space on the telescopic  lid and integrate the different process, safety and cleaning accessories.

The solution brought together the raw material feeding, dust extraction, level control, lighting and cleaning systems within a single piece of equipment, adapting the configuration to the operational requirements of a pilot plant.

What disperser and vessel configurations were considered?

The project was based on the DISPERMIX VF-4-N disperser and included three compatible vessel models:

  • DM-45: its compact dimensions make integration between the internal components and the dispersing disc particularly challenging.
  • DM-90: equipped with a cooling system.
  • DM-200: higher-capacity vessel compatible with the configuration.

Compatibility with these three models allows the equipment to be adapted to different process conditions and production needs, providing flexibility for trials involving the development of new formulations.

DM-45

DM-200                                                                                DM-90 (refrigerated)

How was the batch cleaning system designed?

To facilitate cleaning operations, Oliver + Batlle incorporated a dedicated cleaning head connected to a pneumatic pumping unit, also included in the supply. This system pumps the solvent used for cleaning.

The system enables the equipment and manufacturing vessels to be cleaned at the end of each batch, facilitating product changeovers and reducing the risk of cross-contamination.

This function is particularly important in a pilot plant, where different formulations are processed sequentially and residues from one product must not interfere with subsequent trials.

Pump assembly that circulates the cleaning solvent

What results were achieved with the solution developed for Hempel?

The tests carried out during commissioning confirmed that the solution met the project’s main technical requirements.

Manufacturing versatility

The DISPERMIX VF-4-N demonstrated its ability to process the range of products envisaged for the pilot plant, including high-viscosity formulations.

Effective cleaning between batches

During the trials, the cleaning system enabled product changeovers without cross-contamination issues.

Optimised use of available space

The configuration made it possible to integrate the required process, safety and cleaning components into a compact unit, overcoming the space constraints on the disperser lid.

The project developed for Hempel Polinyà demonstrates how a tailored engineering solution can meet the specific requirements of a pilot plant, even when the available space limits the integration of different components.

By integrating multiple functions into a compact configuration, Oliver + Batlle provided a versatile solution for processing formulations with different viscosities and facilitating cleaning between batches — two essential aspects of new product development.

Do you need a dispersion solution tailored to your manufacturing process?

At Oliver + Batlle, we specialise in designing tailored engineering solutions for the paints and coatings industry. We develop equipment and configurations adapted to the requirements of each process, integrating manufacturing, safety and cleaning functions to meet the operational needs of each facility.

Contact our sales team to discover how we can help you develop a dispersion solution tailored to your manufacturing and new product development requirements.

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Insights on basket milling

Immersion Milling: A technical guide to optimizing coating efficiency 

Immersion grinding is a pigment dispersion and milling process that uses a circular basket mill submerged directly into the product. Unlike horizontal grinding systems, this technology eliminates the need for pumps and hoses, helping to reduce product losses and speed up cleaning operations. It also allows batches of up to 2,000 litres to be processed, with product viscosities of up to 10,000 Centipoises.

But what differentiates the various immersion and circular basket mills available on the market? What features should be considered when selecting the most suitable equipment for each process?

Basket mill technology has become widely established in the coatings industry, and leading equipment manufacturers have developed different ranges and configurations to meet the requirements of each application. Differences in geometry, size, number of agitation shafts, basket configuration and cooling capacity can make selecting the right equipment a complex decision.

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Optimizing immersion grinding: Key takeaways from the Webinar “Basket Mills: Tailoring Accessories and Configurations for Maximum Performance”

At Oliver + Batlle, our commitment to technical innovation and process excellence in the manufacturing of paints and coatings is constant. We recently hosted a technical webinar titled “Basket Mills: Tailoring Accessories and Configurations for Maximum Performance”, presented by our product and technical experts: Miquel Vidal (Mixing & Grinding Product Manager), Adrià Artigas (Laboratory Manager), and Jens Michael Müller (Area Manager).

If you were unable to attend live or wish to review the core concepts discussed, here is a summary of the main technical takeaways and technological trends covered during the session:

The importance of Mill-ennium RS technology and circulation

Immersion grinding using Mill-ennium RS technology allows dispersion and grinding to take place within a single vessel, eliminating the need for transfer pumps and hoses, reducing product losses, and enabling fast color changes alongside simplified cleaning.

During the first part of the webinar, it was emphasized that grinding efficiency directly depends on product turnover (or recirculation rate) through the basket:

  • Performance driven by circulation: Poor circulation creates dead zones, temperature gradients, and slow fineness development.
  • Accessory selection as a process variable: Choosing the right impeller, scraper, or auger is not merely a mechanical option, but a direct process variable affecting rheology and overall efficiency.

Tools and accessories: Tailoring the mill based on viscosity

As viscosity or rheological complexity increases within a formulation, precise accessory selection becomes essential to ensure both continuous feeding into the basket and effective thermal control.

Starting with lower circulation impellers, the standard choice in Mill-ennium technology is the Turbo Impeller, designed to provide a balanced combination of shear and pumping action for low-to-medium viscosity coatings, making it the ideal selection for decorative paints or other products with similar characteristics. As viscosity rises and product mobility decreases, the Turbo + Pumper configuration is utilized; this design incorporates additional paddles to substantially increase the pumping effect, improving overall bulk circulation in structured systems. Meanwhile, the Marine Propeller is primarily reserved for simple mixing tasks or extremely fluid, low-viscosity products.

Unlike other accessories, such as orbital scrapers or vacuum lids, which must be incorporated into the equipment during the design stage, it is important to highlight that Mill-ennium RS units are supplied as standard with both the Turbo Impeller and the Pumper. Switching from one to the other is quick and straightforward.

In scenarios where product viscosity or yield stress prevents natural flow into the basket, the Auger feed screw comes into play. This optional accessory is installed at the basket inlet to force material into the grinding chamber, stabilizing product flow and ensuring optimal basket utilization in challenging high-solids formulations.

Finally, temperature control and batch homogeneity are completed by Scraper Systems. The Orbital Scraper continuously cleans the vessel walls to eliminate stagnant material near cooling surfaces, while also breaking vortex formation and minimizing air entrapment. Laboratory testing shows that its use increases the overall heat transfer coefficient by up to 67% and reduces the product temperature rise by 40% relative to cooling water temperature. For the most demanding applications with elevated viscosities, the Helical Scraper combines wall scraping with dynamic axial pumping, moving material from top to bottom to achieve full-vessel turnover.

Laboratory results and engineering selection matrix

Adrià Artigas presented a series of laboratory trials evaluating flow behavior in HEC (Hydroxyethyl cellulose) water-based systems across various viscosity levels:

Practical tests demonstrated how, at viscosities up to 18,000 cP, combining a Turbo + Pumper + Orbital Scraper + Auger maintains smooth, continuous recirculation without cavitation or overheating.

In summary

The webinar made it clear that optimizing basket mill performance in the paints and coatings sector no longer depends simply on increasing motor horsepower, but on smart management of product circulation and rheology. By leveraging the right combination of impellers, feed screws, and scraper systems, manufacturers can significantly reduce process times, eliminate dead zones, control temperature, and secure highly profitable, efficient production.

Missed It? Watch the webinar replay!

Aligning your equipment configuration with the rheological behavior of your formulations is the benchmark for remaining competitive. If you would like to explore how these technologies can be applied to your dispersion and grinding processes, watch practical laboratory demonstrations, or hear directly from our technical team, we invite you to view the full session recording.

And if you are considering modernizing your milling processes or implementing a more efficient production engineering approach, contact our technical team today. At Oliver + Batlle, we are ready to guide you toward maximum plant productivity.

acabado de pinturas, paint finishing
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The paint finishing stage in the manufacturing process

What does the paint finishing phase involve in the manufacturing process?

The paint finishing phase is one of the final stages of the manufacturing process before filtration and packaging.

Following the dispersion and grinding stages, the product is finished or completed. During this phase, the final liquid components of the formulation—such as resins, emulsions, or solvents—are primarily incorporated using mixing systems with agitation turbines.

Unlike the previous stages, finishing generally requires gentle agitation, tailored to the product’s characteristics, to ensure these components are incorporated uniformly and to achieve proper homogenization.

The goal is to achieve the defined properties of the final product—such as viscosity, density, and color—before the subsequent filtering and packaging stages.

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New water-based coating manufacturing and filling plant: Process optimization at EUROTEX

EUROTEX: Manufacturing and marketing of industrial and decorative paints, and waterproofing products

EUROTEX began its business activity in the early 1980s as a specialized paint store in Mairena del Alcor, Seville. In 1987, aimed at gaining greater control over its production processes, the company started manufacturing the products it sold and established its factory and headquarters in El Viso del Alcor.

Currently, EUROTEX manufactures and markets a wide range of products, including industrial and decorative paints, primers, sealers, and waterproofing materials.

What product does the plant manufacture?

The project was focused on the manufacture of water-based paints and other water-based products.

The process is carried out in two tanks, where the dispersion and finishing stages of the formulation take place. The product then passes through a pumping and filtration system before filling.

The Challenge: Design and integrate a new water-based coating production unit

EUROTEX needed to install a new production unit for water-based products, consisting of a Dispermix VF-132-E high-speed disperser, two DE-7200 tanks, an MF-16 pumping and filtration unit, and a FLASH-21 volumetric filling machine.

The project presented three main constraints:

  • Tight Delivery Schedule: The installation had to be operational prior to the start of the production campaign, requiring a particularly demanding delivery schedule.
  • Limited Available Space: The new unit had to be integrated into an area with space and height restrictions. O+B designed a dedicated platform to accommodate the manufacturing equipment, taking into account the existing access points, its connection to an existing platform, and pallet access through safety gates.
  • Integration with third-party systems: The dispersion equipment had to be integrated with the solid and liquid feeding systems supplied by another vendor, requiring coordination among the different parties involved.

Oliver+Batlle’s Solution: A coating manufacturing unit tailored to space and process needs

Industrial machinery supplied for the production process

To meet the project requirements, O+B supplied the following equipment:

  • Industrial disperser: One Dispermix VF-132-E, equipped with a motorized crown for automatic head rotation, a telescopic cover with blade access port, an HDM Ø675 mm dispersion blade, and a bag support tray.
  • Process tanks: Two DE-7200 tanks to be installed on the platform, configured with a loading manhole and the necessary connections for powder and liquid addition, as well as dust extraction.
  • Pumping and filtration system: One MF-16 pneumatic pumping and filtering unit, designed for pumping and filtering the product manufactured in the DE-7200 tanks prior to filling.
  • Automatic filling line: One FLASH-21 volumetric filling machine, featuring a TA-100-HD hygienic hopper, NE-20 electronic level sensor, AV-20 valve with actuator, SLT-20 cleaning system, and DT-350 lid dispenser.

Plant layout engineering, assembly, and commissioning

In addition to supplying the equipment, O+B developed the plant layout engineering for the various elements located both above and below the platform: disperser, DE-7200 tanks, pumping unit, and automatic volumetric filling machine.

To accurately define the equipment layout, site measurements were taken beforehand, and construction drawings for the manufacturing platform were prepared and agreed upon with the client.

The platform was designed and engineered by O+B and manufactured and installed by a third party.

Mechanical assembly of the equipment was carried out by an O+B technician. Moving the disperser and tanks into position posed an additional challenge due to the limited space and height available, requiring close coordination with the crane contractor appointed by EUROTEX.

Electrical and pneumatic installation works were carried out by the client and subsequently supervised by an O+B technician.

Finally, O+B carried out the plant commissioning, starting up and adjusting the machines for normal operation.

Platform layout drawing designed and calculated by Oliver + Batlle

3D structural drawing of the platform

Plant layout drawing of the Dispermix VF-132-E and two DE-7200 tanks

Project Results

The new manufacturing unit enables EUROTEX to produce water-based coatings and meet customer demands in terms of both quality and turnaround times.

One of the main operational advantages of this configuration is the ability to stagger production and filling between the two tanks: while a batch is being filled from one tank, production of another batch can begin in the second tank.

This increased operational flexibility substantially enhances the plant’s overall production capacity.

Are you planning to expand your plant or add a new water-based paint manufacturing line?

At Oliver + Batlle, we specialize in the design and execution of custom process engineering projects for the paint and coatings industry. We develop turnkey solutions for the manufacture of water-based paints, varnishes, adhesives and inks, integrating dispersion equipment, filtration systems, filling lines and working platforms to maximize the efficiency, safety and productivity of your facilities.

Get in touch with our engineering team today to find out how we can help you expand your production capacity and integrate new equipment into your plant without disrupting your operations.