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Automation of additive dosing for the manufacture of water-based coatings: Puma Group case study

Puma Group and its coatings division

Grupo Puma  is a leading business group in the construction materials sector and the largest manufacturer of mortars in Spain. With over 40 years of experience, it develops a wide range of solutions for construction, including adhesives, insulation systems, flooring, asphalt products and renovation solutions.

The group also has a division specialising in coatings, both water-based and solvent-based, for the manufacture of waterproofing and decorative paints for façades and fillers that can be applied to different surfaces. It currently has 37 production centres and a distribution network spanning four continents.

Product to be processed and project objective

The client manufactures coatings and coverings mainly for the construction sector. Within the framework of this project, the installation of additives is intended for the production of water-based coatings.

The incorporation of additives during the manufacture of paints and coatings is common practice in the industry, as they allow various properties of the final product to be adjusted and improved. Their functions include improving the dispersion of pigments and fillers (dispersants), controlling foam generated during the process (defoamers), stabilising the system by adjusting the pH, and providing specific properties such as biological resistance, gloss control, or modification of drying times.

These additives are normally used in small quantities and are incorporated at different stages of the manufacturing process, which requires precise and repeatable dosing to ensure the quality and homogeneity of the final product. They are usually supplied in industrial containers such as IBCs or 200-litre drums, so in many plants weighing and addition are done manually.

In this context, the aim of the project was to design and implement an automated system capable of managing the weighing and precise dosing of different additives into eight independent dispersion tanks. The installation had to guarantee speed, accuracy and repeatability in the additions, integrating into the existing production process and allowing the direct use of IBCs as storage tanks for the additives. The aim was to avoid frequent transfer or replacement of containers, optimise internal raw material logistics and improve the overall efficiency of the manufacturing process.

Oliver + Batlle solution

To solve the challenge, Oliver + Batlle designed an automated additive dosing system comprising the following main elements:

  • A 300-litre additive weighing hopper, made of stainless steel and equipped with load cells. It incorporates automatic valves for dosing 11 different additives: 9 of them dosed by gravity and 2 by pumping, due to their higher viscosity. The system also has manual valves with micro-switches for loading the stock IBCs of each additive.
  • Two pneumatic pumping units, designed for dosing higher viscosity additives.
  • A pneumatic transfer pump, responsible for transferring the product from the weighing hopper to any of the eight possible destinations.
  • A stainless steel distribution manifold equipped with seven automatic three-way valves, allowing the destination of the additive to be selected.
  • Eight automatic line shut-off valves, installed at the inlet of each of the dispersion tanks.
  • An electrical control and manoeuvring cabinet, equipped with a PLC and HMI touch screen, from which the operator can select the additive to be dosed, define the weight set point, manage stock loading and monitor the operation of the installation.
  • Two portable pump units on trolleys, designed for loading IBCs of additive stock.

Oliver + Batlle carried out all the engineering work for implementation at the plant, including the distribution of the additive IBCs, the weighing hopper, the pumping equipment and the layout of the pipes from the hopper to the collector and from there to the dispersion tanks.

The mechanical, electrical and pneumatic assembly was carried out by the customer themselves, under the supervision of an O+B technician.

Subsequently, the installation was commissioned with the participation of a mechanical technician and an Oliver + Batlle programmer.

During operation, additives compatible with each other are dosed and weighed in the hopper, from where they are automatically transferred to the selected dispersion tank. The system also incorporates a water cleaning cycle for the hopper and  flushing of the pipeline, ensuring that all the additives reach its destination.

The additive dosing control system was integrated into the factory’s automated system for executing complete recipes using the customer’s SCADA, establishing communication between the PLC of the system supplied by Oliver + Batlle and the plant’s main PLC.

3D views of the additive storage and distribution system: stock IBCs, 3-way valve manifold and piping to dispersion tanks

Results and advantages of the implemented solution

Thanks to the implementation of this automated additive dosing system, the customer has significantly optimised manufacturing times.

The process has gained in precision, cleanliness and repeatability, eliminating the variability associated with manual dosing.

In addition, the system provides complete traceability of the process, recording the dosages carried out for each batch, including the additive code, target value, actual dosage value, destination, date and time of the operation.

Automation has also reduced the operational workload, minimising manual interventions and facilitating the work of the plant operator.

 

The main advantages of the implemented solution are:

  • Automation of the additive dosing process.
  • Greater precision and repeatability in each manufacturing batch.
  • Optimisation of process times.
  • Improved cleanliness and order in the plant.
  • Complete traceability of dosages performed.
  • Reduction in operator workload.
  • Integration with the existing control system through communication between PLCs.
  • Direct use of IBCs as additive stock tanks, optimising internal logistics.

Do you need to automate dosing in your production plant?

At Oliver + Batlle, we specialise in process engineering design and customised automation for the chemical and coatings industry. From upgrading existing lines to designing turnkey production plants.

Contact our technical team today  and find out how we can help you optimise your cycle times, improve traceability and make your manufacturing process more profitable.

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Revolution in paint dosing: Why the future is additive (3D)

In the paints and coatings industry, efficiency is not just a goal; it is a competitive necessity. However, many production lines are still held back by conventional dosing technologies that create bottlenecks, product waste, and high maintenance costs.

At Oliver + Batlle we have launched a 3D additive manufacturing nozzle service that does not just sell a product, but optimises your entire packaging process.

Why switch from traditional metal nozzles to 3D technology?

Additive manufacturing allows us to design “layer by layer”, breaking the limitations of traditional machining and offering tangible benefits in three critical areas:

1. Increased productivity and profitability

  • Manufacturing speed: Our nozzles allow for up to a 20% increase in filling speed compared to conventional dosers.
  • Time optimisation: Reducing the seconds per dosing cycle is the most direct way to increase your daily output.
  • Cost reduction: Improved efficiency, together with annual contract options including 10% discounts, significantly reduces the total cost of ownership.


2. Packaging quality: Zero drips, zero foam

One of the biggest challenges in paint packaging is difficult products that generate foam or residual dripping.

  • Precision design: Each nozzle is custom-designed for the specific rheology of your product.
  • A diameter for every container: We apply the principle of an optimal nozzle according to the container diameter, ensuring a millimetre-perfect fit and an impeccable finish.


3. Technical superiority of the material

Unlike heavy metal parts, our 3D nozzles offer:

  • Minimum weight: Reduces mechanical stress and wear on the dosing arms of your machines.
  • Greater impact resistance: Manufactured with high-durability technical polymers that withstand the pace of an industrial plant.
  • Ad-hoc flexibility: The process begins with a preliminary study and the development of a functional prototype to ensure the solution is perfect before final production.


A service model designed for your business

We understand that production varies, which is why our model is fully flexible. We offer a service with no long-term commitment which includes:

  • Personalised study and design.
  • Scheduled deliveries to guarantee your stock.
  • Express service: Deliveries within 24 hours in Europe and 72 hours in the rest of the world for urgent situations.


Conclusion

The digitalisation of dosing is here to stay. With Oliver + Batlle’s 3D nozzles, your company not only gains speed, but also a packaging quality that your customers will notice from the very first tin.

Are you ready to transform your production line? To discover the potential savings and see our rates (with nozzles starting from €180), contact our sales team today.

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Equipment for the Manufacturing of Emulsion Paints and Coatings

Company overview

Duracolor Coatings, S.L.U. is a family-owned company dedicated to the manufacture of a wide range of coatings, both water-based and solvent-based, including emulsion paints, exterior coatings, primers, enamels, varnishes and wood finishes.

With a strong industrial background dating back to the 1980s, Duracolor markets its products both in the domestic market and internationally, particularly in South America and Africa, through specialised distributors. Throughout its history, the company has continuously invested in improving its production processes to meet growing demands for quality, flexibility and capacity.

Product to be processed

Water-based emulsion paints and exterior coatings.

Project objective

Duracolor Coatings identified the need to increase the production capacity of its water-based product range (emulsion paints and exterior coatings), under a number of key technical constraints:

  • Installation of the new equipment in a limited space, adjacent to the existing dispersion area, originally supplied by Oliver + Batlle in the late 1990s.
  • Close coordination with the different contractors involved in the project, including:
    • Manufacturer of the working platform.
    • Installers of solid and liquid feeding systems.
    • Dust and vapour extraction systems integrated with the Oliver + Batlle equipment.

The objective was to integrate the new manufacturing units while maintaining production continuity, optimising the use of available space and ensuring appropriate safety, ergonomics and operational efficiency.

Oliver + Batlle solution

Oliver + Batlle designed and supplied a solution fully adapted to the specific requirements of Duracolor’s plant, including the following equipment:

  • Polimix DPS-8000-OR, standard power, equipped with:
    • Integrated weighing system.
    • Automatic discharge valves.
    • Fixed cleaning lances.
    • Cleaning pump unit GLP-10/S-30.

  • MF-16 pumping unit with filter, for transferring the paste produced in the Polimix to the finishing tanks.
  • Three TA-12000-PS finishing tanks, each equipped with:
    • Weighing system.
    • Automatic discharge valve.
    • Fixed cleaning lances.

Dynamic load calculations for the existing structure were provided, and the final location of the Polimix and the finishing tanks within the available space was jointly agreed, arranging them in a triangular (staggered) layout in order to optimise access, traffic flow and operational accessibility.

In addition, the position and sizing of the following were also jointly defined:

  • Liquid and powder feeding connections for the Polimix unit.
  • Dust and vapour extraction systems for the Polimix unit.
  • Liquid feeding connections and vapour extraction for the Finishing Tanks.

Process flow diagram of the supplied equipment

Results

As a result of the implemented solution, Duracolor Coatings has significantly increased the production capacity of its existing plant.

  • The Polimix is used for the paste preparation stage, incorporating water, powders and additives.
  • The paste is then transferred to the Finishing Tanks, where the formulation is completed by adding emulsions, water and final additives.

This production concept allows overlapping operations: while a batch is being finalised in a finishing tank, a new paste can be prepared in the Polimix. As a result, manufacturing times are optimised, overall plant productivity is improved, and the quality and homogeneity of the final product are ensured.

 

 

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Manufacturing and Filling of Solvent-Based Industrial Paint

Introduction

A leading company in the industrial paints and coatings sector undertook a strategic project aimed at optimising its manufacturing and filling processes for solvent-based industrial paint. The objective was to implement a highly automated installation capable of handling complex formulations, multiple raw materials, and different batch sizes, whilst maintaining the highest standards of quality, safety, traceability, and environmental responsibility.

Oliver + Batlle participated in the development and implementation of the technological solutions required to meet these objectives, contributing its expertise in dosing systems, manufacturing processes, and process control for the paints industry.

Product to be processed

The project focused on the manufacturing and filling of solvent-based industrial paint, intended for the protection and decoration of surfaces, with high requirements in terms of homogeneity, repeatability, and final product performance.

Project objectives

The company sought a solution that would enable the manufacturing and filling of a wide variety of products, in different batch sizes, through fully automated and highly controlled processes.

The main technical challenges of the project were:

  • Management of a large number of raw materials, with more than 60 different products, including solids and liquids, many of them transferred via piping.
  • Ensuring the required quality for each formulation, regardless of its complexity.
  • Guaranteeing full traceability of raw materials and process operations.
  • Maintaining optimal safety and hygiene conditions, with a design focused on zero pollution, for both solids and liquids, despite working with solvent-based products.
  • Fully automating the production process through recipe execution from the control system.

Solutions provided by Oliver + Batlle

Oliver + Batlle developed and integrated a set of process and automation solutions, specifically designed to meet the requirements of a leading manufacturer in the sector.

Solid dosing and conveying

For the handling of solid raw materials, the following solutions were implemented:

  • Installation of four 6 m³ mini-silos for powder raw materials, with automatic transfer through a pneumatic conveying system running throughout the plant to the different consumption points.
  • Dosing station for solids not stored in silos, supplied from bags or big-bags, with direct pneumatic conveying to the dispersers used for large-batch production.
  • Mechanical conveying system with a capacity of up to 6 t/h, designed to automatically feed and dose solids to four dispersers located on the process platform.

Liquid dosing

The solution incorporates an automatic liquid dosing system, integrated into recipe management, enabling precise dosing of:

  • Major raw materials, such as resins and solvents.
  • A large number of additives, managed according to defined formulations.

Manufacturing and finishing processes

The Mill Base is manufactured in single-shaft and three-shaft dispersers, from which the product is transferred to intermediate tanks through milling processes.

The milled products are then transferred to finishing tanks of different capacities, equipped with mixing systems specifically designed according to the type of product and its rheological requirements.

Small-batch production

The solution combines large-batch manufacturing with short-run production through:

  • Four automatic dosing stations, capable of managing multiple different products per recipe.
  • Dosing heads with horizontal movement, facilitating manual dosing from drums.
  • A set of 19 process units, including dispersers, mixers, and milling systems, dedicated to small-batch production.

Automation and traceability

The entire installation is governed by a fully automatic control system, with recipe management and communication with the customer’s ERP, enabling centralised control of all manufacturing operations.

In addition, a barcode creation and reading system was integrated for manually added products, ensuring complete traceability of raw materials and the production process.

Results

The implemented solutions allow this leading company to operate a highly flexible, safe, and efficient industrial paint manufacturing and filling system, capable of handling a wide variety of formulations and batch sizes.

Key benefits achieved:

  • High production flexibility, adapted to a broad product portfolio.
  • Full automation, ensuring accuracy, repeatability, and process control.
  • Maximum safety and hygiene, with a plant designed to operate under zero-pollution conditions.
  • Strong environmental commitment, even in processes involving solvent-based products.

Our technical team can help you define the most suitable solution for your process

 

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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.