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Case study PINTURAS MONTÓ – Continuous production and automated filling of decorative paint

1. Company Overview

Founded in 1961, Pinturas Montó began its activity in Valencia producing vegetable glues and traditional tempera paints. Over the years, it evolved into the manufacture of decorative plastic paints, becoming a benchmark brand in the sector.

Since 1996, the company has operated from its 46,000 m² facility in Marines (Valencia), equipped with advanced manufacturing and quality-control technology. Montó maintains a firm commitment to innovation, sustainability and international expansion, achieving a production capacity of over 200,000 L per day with a consolidated presence in multiple countries.

 

2. Product to be processed

Pinturas Montó offers a complete product range for the decorative and professional markets, including:

  • Interior plastic paints (matt, mid-sheen and satin).
  • Exterior façade coatings (siloxanic, monocapa, SATE systems).
  • Water-based enamels for multiple substrates.
  • Fillers, primers and surface-preparation products.
  • Tinting systems with bases, colourants and proprietary software.
  • Technical coatings: damp-proof, intumescent, wood protection and sports-floor coatings.

 

3. Project objective

Pinturas Montó identified the need to increase its production capacity for manufacturing large batches of white water-based paint, both for its own brand and for third parties. The main objective was to achieve a continuous, stable and highly efficient production flow, optimising time, resources and operating costs.

Although the company already had process equipment, the rise in demand required a fully automated line capable of integrating:

  • Manufacturing
  • Filling
  • Palletising

The installation also had to handle two different container ranges simultaneously:

  • Small formats (up to 5 L)
  • Large formats (up to 20 L)

This led to the design of a dual-line, high-output filling system, ensuring the performance, accuracy and efficiency required by Pinturas Montó.

 

4. Oliver + Batlle solution

Oliver + Batlle provided a comprehensive solution combining continuous production, automated filling and in-line quality control.

Production

A Dispermix VF-400-E was installed together with two 20,000-L tanks positioned on the customer’s existing platform.

This setup allows:

  • Manufacturing a new batch while the previous one is being filled
  • Eliminating downtime
  • Maintaining a constant feed to the filling lines

Automatic filling – dual line

Two automatic lines with a common structure were implemented:

Filling line for large-containers (up to 20 L)

Featuring:

  • Automatic pail denester PAILMANAGER
  • Automatic labelling machine
  • Flash-25-T , volumetric filling machine including:
    • Two dosing heads
    • Two independent hoppers
    • Lid dispenser and closing unit
    • Checkweigher with automatic correction
    • Rejecting system

The checkweigher communicates with both dosing heads, automatically adjusting volumes according to variations in the paint’s rheological behaviour.

Filling line for small-containers (up to 5 L)

Featuring:

  • Semi-automatic feeding table SQ
  • Automatic labelling machine
  • Volumetric filling unit Flash-55-S, equipped with a single dosing head and offering similar features to the Flash-25-T , optimised for smaller formats.

 

5. Results

Continuous production: While one 20,000-L tank feeds the filling lines, the next batch is manufactured in the second tank, ensuring constant flow and eliminating downtime.

Reduced cleaning time: As the line works exclusively with white paint, cleaning is required only once a week, significantly reducing downtime and associated costs.

Increased productivity: Full automation and the ability to handle up to 29 different formats enable Montó to meet both internal demand and third-party production with greater flexibility and speed.

 

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Thixotropy: The Definitive Guide to Paint Manufacturing

Introduction

If your manufacturing process for paints, sealants, or putties involves a change in viscosity when stirred, you are working with thixotropy. But do you know how to measure and control this phenomenon to guarantee consistency in the container and ease of application?

Thixotropy is the fundamental rheological property by which some complex fluids drastically modify their viscosity, becoming more fluid, when a shear force (such as stirring) is applied to them. This phenomenon is key: the fluid has a high equilibrium viscosity at rest and “liquefies” during working.

Below, we will delve into the concept, explore the crucial difference with pseudoplastic fluids, and analyse how thixotropy determines the choice of the most efficient machinery in the manufacturing, finishing, and packaging phases of your products.

1. What Thixotropy is and Why it is Crucial in Viscosity

The technical concept of thixotropy involves the decrease in viscosity over time under a constant stress or shear rate, followed by a gradual recovery of the original viscosity (equilibrium viscosity) when that stress ceases.

Think of it this way: the paint in the pot is thick (high equilibrium viscosity), but when stirred or applied with a brush, it becomes fluid (low viscosity), allowing for application. Once on the wall, the shearing ceases and the product quickly recovers its initial viscosity, preventing sagging.

1.1. The Key Difference: Thixotropic vs. Pseudoplastic

It is common for thixotropy to be confused with the behaviour of pseudoplastic fluids. Although both show a decrease in viscosity with shearing, the time difference is fundamental:

1.2. Rheopectic: The Opposite Behaviour (Anti-Thixotropy)

In contrast, fluids that exhibit the opposite behaviour to thixotropy, where constant stirring causes solidification or an increase in viscosity over time, are called rheopectic or anti-thixotropic. These products are significantly less common in the coatings industry.

thixotropy vs pseudoplastic

2. Thixotropy and Manufacturing: The Demand on Industrial Machinery

Thixotropy does not affect all formulations equally. Products such as varnishes, lacquers, and traditional synthetic and water-based paints are usually non-thixotropic. However, highly specialised products such as wood sealants, waterproofing paints, and repair putties are eminently thixotropic.

When selecting manufacturing machinery, it is imperative to know the level of thixotropy of the product. The stirring equipment must meet two key requirements to ensure homogeneity:

  1. Offer the adequate power to break the fluid’s initial thixotropy.
  2. Maintain a constant speed for the time necessary to reach the optimum working state.

2.1. Specific Equipment for High Thixotropy Products

The equipment from Oliver + Batlle is designed to manage these rheological challenges with high efficiency:

  • Dual Dispermix: Suitable for medium and high viscosity products that exhibit moderate thixotropy.
  • Hidrobat Planetary Mixer: The ideal solution for high viscosity and very thixotropic products (and also pseudoplastic ones), ensuring intensive and uniform working.

mezcladores productos tixotropicos

It is important to remember that, once manufactured and agitation has stopped, the product cools and increases its viscosity, acquiring the appropriate rest state for its final application.

 

3. The Thixotropic Packaging Challenge: Dosing and Pumping Solutions

The packaging of thixotropic products presents its own set of challenges, the main one being the difficulty of extracting the product from the container due to its high equilibrium viscosity.

3.1. Tank Emptying: Hydraulic Presses and Volumetric Equipment

To facilitate the emptying of portable tanks (which often reach 1,500 litres), high-force extraction equipment is required:

  • Hydraulic Press Systems (PH or PCH – TVH Press): The pressing pressure is capable of extracting medium and high thixotropic viscosity products that would otherwise be impossible to pump at rest.

Once out of the tank, the most precise measuring and dosing systems are volumetric type (such as the DVB 250), which can be easily automated with container conveying and closing systems.

3.2. Industrial Filling Machines: Gravimetric and Positive Displacement

In the Oliver + Batlle portfolio, we have specific solutions for different capacities:

  • Low Volume Filling Machines (E.g., Model EM 52): Designed for packaging highly thixotropic and high viscosity products in containers of up to 250 cc (common in offset inks or repair putties).
  • High Volume Filling Machines (E.g., DG 60 or OB 130): These gravimetric filling machines are fed by electric positive displacement screw pumps, as these better handle the high viscosity and nature of the fluid.

Process Note: To avoid suction problems in the pumps, it is vital that thixotropic products remain under agitation in the finishing tank during the packaging phase.

Conclusion: The Need for Rigorous Control

Thixotropy is a complex but essential property for the final quality of specialised coatings. Understanding the difference with pseudoplastic fluids and applying the correct stirring and extraction regime not only guarantees a homogenous product but also optimises the packaging process.

Do not risk the quality of your formulation. If you want to guarantee that your thixotropic products are manufactured and packaged with maximum efficiency and according to specifications, you need the right machinery.

Act Now! We invite you to contact the Oliver + Batlle specialists directly to request technical advice and discover which equipment (stirrers, presses, or filling machines) best suits the exact profile of your products.

 

 

 

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How to Measure and Control Paint Quality (Viscosity, Color and Gloss)

Do you really know if your paint batch will meet the required specifications for finish, durability and application?
In the demanding process of coatings manufacturing, quality control is not optional—it is the guarantee of performance. Properties such as viscosity, specific weight or color must be continuously verified to ensure that the final product is not only applicable but also delivers the expected result to the customer.

In this technical guide, we will thoroughly analyze the 7 fundamental characteristics you must control in your production process. Discover the methods, units of measurement and key equipment to master paint control and take the quality of your formulation to the next level.

1. Paint Viscosity: Concept, Units and Essential Measurement

Viscosity is defined as the internal resistance of a liquid to flow or be poured. This resistance originates from the friction between the molecules of the fluid. It is essentially the opposite characteristic to fluidity: the greater the fluidity, the lower the viscosity.

The official unit of measurement in the International System (SI) is Pascal-second (Pa·s), although Poise is traditionally used. In the industry, its submultiple, the centipoise (cP), is frequently used, since water has a viscosity of 1.0020 cP at 20 °C (1 cP = 1 mPa·s).

Key Technical Note: Temperature has a dramatic influence on viscosity. Reporting the measurement temperature is mandatory; in the paint industry, it is typically measured at 25 °C.

There are three leading types of devices used to measure paint viscosity:

1.1. Efflux Cups: Ford, Zahn and Gardner (Flow Time)

These devices operate based on “flow time.” They measure the time, in seconds, it takes for a fixed volume of liquid to flow through a calibrated orifice (with different cup numbers). They are fast and easy to use, widely applied in inks and adhesives manufacturing, although they are not recommended for non-Newtonian fluids (whose viscosity varies with applied shear).

1.2. Stormer Viscometer: Measuring Viscosity in Krebs Units (KU)

The Stormer viscometer uses a standardized paddle that rotates when weight is applied. The time required to complete 100 revolutions at a given weight is measured. Results are expressed in Krebs Units (KU), using a reference chart such as ASTM D562.

1.3. Brookfield Viscometer: Rotational Viscosity Measurement (cps)

This system measures viscosity by detecting the torque required to rotate a spindle at constant speed while immersed in the fluid. The reading is given in centipoises (cps).

Attention: For correct measurement, it is crucial to take the reading at the same moment from the beginning of agitation, especially in thixotropic products, whose viscosity can vary with time under shear.

  • Pycnometer: A container with a known volume (e.g., 100 cc) with a cap that includes an overflow. It is filled, weighed with a precision balance, and its known volume allows for very accurate determination of density or specific weight.

  • Graduated cylinder: A calibrated cylinder (e.g., 100 cc) can also be used; although the procedure is similar to the pycnometer, results are less precise.

3. Thixotropy: The Phenomenon of Viscosity Reduction Under Shear

Thixotropy is a fundamental property in paints and many inks. It is the ability of some liquids or gels to decrease their viscosity when shear stress (agitation) is applied.

When the liquid is at rest, particles are randomly oriented, resulting in high viscosity. When agitated, particles align in the direction of flow, allowing them to slide past each other more easily and, therefore, reducing viscosity.

4. Grind Fineness: Dispersion Quality and Its Impact on Finish

Grind fineness is a direct indicator of the degree of dispersion of a paint; that is, the approximate maximum diameter of pigment and filler particles.

This parameter is critical because an inadequate value directly affects:

  • Final color and gloss

  • Corrosion resistance

  • Sedimentation, flocculation and floating problems

The most commonly used instruments to measure grind fineness are grind gauges (grindometers), microscopes with image analysis and laser-based systems.

5. Paint Color: Measurement, Coordinates and Spectrophotometry

Color is a subjective visual sensation, but its measurement must be objective and precise. To define color in the industry, three elements are required: the object, the illuminant and the detector.

Accurate color measurement is carried out using the CIELab system, based on a reflectance curve. This system defines:

  • L: Lightness (more or less white/dark)

  • a and b: Chromaticity (hue and saturation)

The key instrument is the reflectance spectrophotometer, which not only calculates the reflectance curve and coordinates but is essential for color matching, determining the exact amounts of colorant required.

5.1. Tinting Strength: Pigment Coloring Power

Tinting strength is the ability of a pigment or paint to color when mixed with white or another color.

It is measured using the ratio “colored pigment / white pigment” required to achieve a defined standard depth of color. The analysis is performed with the spectrophotometer on film applications of both sample and standard.

5.2. Hiding Power (Opacity): How to Cover the Substrate

Hiding power is the ability of paint to conceal the color of the surface onto which it is applied (opacity).

It depends on the type and percentage of pigment and, fundamentally, on the relationship between the refractive indices of the pigment and the medium. The greater the difference between the indices, the higher the hiding power.

It is measured through the contrast ratio (CR = Rn/Rb), which indicates how close the paint is to full coverage, by comparing reflectance over black-white contrast charts using a spectrophotometer.

6. Gloss: Specular Reflection and Measurement by Angles (Glossmeter)

Gloss or specular reflection is the ability of the paint film to reflect incoming light. The smoother the surface, the higher the gloss. This property depends mainly on the type of resin used.

Gloss is measured with a reflectometer or glossmeter at specific angles depending on the finish:

  • 20°: very glossy surfaces

  • 60°: medium gloss surfaces

  • 85°: matte or near-matte surfaces

Results are expressed as the percentage of light reflected compared to a reference standard, taken as 100.

7. Additional Controls in Paint Manufacturing and Conclusion

Mastering viscosity, color and hiding power is essential, but quality control does not end there. In liquid paint manufacturing, stability, flocculation, flexibility and skin formation must also be analyzed. In dry paint, factors such as film thickness, hardness, adhesion and washability are controlled.

The quality of your final product depends directly on the precision of your control and manufacturing equipment.

At Oliver + Batlle, we hope this technical guide will be extremely useful to you in optimizing your processes. If you are looking for mixing, dispersion or packaging solutions that ensure rigorous compliance with these characteristics, we invite you to consult our industrial machinery catalog or contact our expert team for personalized advice.

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Oliver + Batlle will share its latest innovations at Paint & Coatings 2025

Oliver + Batlle will be present at Paint & Coatings 2025, the leading trade fair for the paints, inks and coatings sector, to be held on 19–20 November in Barcelona.
Since its first edition, this event has become an essential meeting point for manufacturers, suppliers and technical professionals — a space to explore the latest trends and technological solutions shaping the industry.

With over 65 years of experience in the design and manufacturing of equipment for the production of paints and coatings, Oliver + Batlle reaffirms its commitment to innovation and customer proximity.
At this new edition of Paint & Coatings, the company will showcase its comprehensive range of solutions for dispersion, mixing and packaging processes, designed to enhance quality, productivity and sustainability in production.

Technological solutions for a more efficient and sustainable industry

At our stand, visitors will discover the latest innovations in industrial manufacturing equipment and process systems engineered to deliver efficiency, flexibility and control in production.
O+B solutions combine traditional mechanical robustness with advanced control software, ensuring optimal adaptation to each manufacturer’s needs.

Among the innovations presented are our smart packaging systems and process optimization technologies for dispersion, which help reduce energy consumption, increase process precision and ensure consistent quality across production batches.

Through these developments, Oliver + Batlle continues to drive the transition towards safer, more efficient and sustainable manufacturing, aligned with the industrial development and sustainability goals shaping the sector’s future.

Participation in the TechFocus programme

Once again, Oliver + Batlle will take part in the TechFocus programme, one of the most valued spaces of the event for its technical and informative orientation.

This year, Adrià Artigas, Laboratory Manager at O+B, will present the session “Testing laboratory to determine the most efficient solution for each need”, addressing how we support our clients from the initial concept to final product validation through tests, trials and technical consultancy.

Attendees will discover how our laboratory team works closely with manufacturers to validate new technologies, adjust production parameters or test new products under real conditions.
This technical proximity is one of Oliver + Batlle’s distinguishing values — a comprehensive support approach that goes beyond equipment supply and puts knowledge at the core of service.

A commitment to innovation and proximity

Participation in Paint & Coatings 2025 represents a new opportunity for us to connect with clients, partners and professionals from the paints and coatings industry, and to share our vision of a more advanced, digital and sustainable industry.

We look forward to seeing you at Paint & Coatings 2025

We invite all professionals in the sector to visit us and discover first-hand the solutions we offer to optimize manufacturing, dispersion and packaging processes.

Our team will be delighted to welcome you and exchange insights on the challenges and opportunities shaping the future of the industry.

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High output filling of stucco products for JOTUN

Introduction

In the paints and coatings sector, efficiency in manufacturing and packaging processes is key to ensuring competitiveness and maintaining high quality standards. In this context, JOTUN, one of the most renowned paint and coatings manufacturers worldwide, entrusted Oliver + Batlle to carry out a strategic project to automate its high-cadence packaging lines.

Company overview

Jotun is one of the world’s leading manufacturers of paints and coatings, with almost a century of expertise in protecting and beautifying surfaces across all industries. From iconic architectural landmarks to residential projects, Jotun has established itself as a trusted partner thanks to its commitment to quality, innovation, and sustainability.

The company operates across a wide range of market segments:

  • Decorative paints for interior and exterior applications.
  • Architectural and design coatings providing both performance and aesthetics.
  • Infrastructure protection for industrial and large-scale projects.
  • Light industry with advanced powder coatings.
  • Shipping with marine coatings.

  • Energy sector with protective and powder solutions.

Jotun’s continuous investment in research and development reflects its focus on delivering environmentally friendly technologies and high-performance products.

Product to be processed

The project focused on stucco and wall putties for interior use, products that require precise and reliable handling due to their physical properties:

  • Specific gravity: up to 2.2 kg/dm³
  • Viscosity: medium range, up to 6000 cP

These formulations are specifically designed to provide excellent surface preparation, offering a smooth and uniform base layer for subsequent paint or coating applications.

Project objective

The customer’s objective was the supply of two complete high-speed filling lines for stucco and putty products, designed to deliver:

  • Packaging flexibility: from 0.9 L to 20 L (both pails and cans).
  • Universal configuration: each filling line capable of handling the entire range of formats.
  • Integrated discharge and pumping systems: dedicated tanks and pumping units for optimal feeding of the filling machines.

The ultimate goal was to achieve high output, reliable performance, and automated changeovers, ensuring consistent productivity and minimal downtime.

Oliver + Batlle solution

Oliver + Batlle supplied a fully integrated solution, combining precision filling technology with robust automation and handling systems.

Key components of the project included:

  • Pumping system: progressing cavity pumps installed beneath the product tanks, connected directly to the dosing heads for smooth and efficient product transfer.
  • Container handling:
    • Pail denester PAILMANAGER for conical stackable buckets.
    • Infeed table DB-SQ and conveyor for cylindrical cans.
  • Labelling: automatic labelling unit integrated into the line.
  • Filling and closing: FLASH-25-T filling line, including automatic lid placing, lid closing, and integrated checkweigher.
  • Automation: complete line with automatic format changeover for each machine.

Performance achieved:

  • Up to 20 containers/minute for 10 L buckets.
  • Up to 17 containers/minute for 20 L buckets.

Results achieved

The implementation of this solution has successfully met — and even exceeded — the customer’s expectations. The lines delivered:

  • High-speed performance: achieving the specified outputs with maximum accuracy.
  • Robust and reliable operation: guaranteeing long-term consistency without unplanned downtime.
  • Sustainable performance: aligned with Jotun’s strict quality and sustainability standards.

This project highlights Oliver + Batlle’s ability to design and implement turnkey filling solutions for high-viscosity stucco and putty products, ensuring efficiency, flexibility, and operational excellence.

Customer testimonial

“We are very satisfied with the project delivered by Oliver + Batlle. The installed filling lines have not only met but exceeded our expectations, achieving the desired filling rate and significantly improving operational efficiency. The solution is highly reliable and robust, with consistent performance and no failures.”