The production of resins for printing inks requires highly controlled processes, particularly when new equipment must be integrated into existing industrial facilities with ATEX safety requirements. In this project, Oliver + Batlle developed a turnkey solution for Sakata INX Spain, incorporating a new 6,000-litre reactor together with all the auxiliary systems required for its operation, while ensuring seamless integration with the existing plant and full compliance with the client’s process and safety requirements.
Sakata INX: Technology for printing ink manufacturing
Sakata INX is a Japan-based multinational company recognised worldwide for its leadership in the development and manufacture of printing inks for the graphic arts and packaging industries.
In Spain, Sakata INX España, S.A. operates production facilities equipped with advanced technologies for the manufacture of varnishes, resins, and pigment dispersions.
The project focused on the production of a resin used as a raw material in the manufacture of white bases for printing inks applied to flexible plastic packaging.
This white base is one of the most critical layers in the printing process, acting as an opaque background onto which the final graphics and colours are printed. The quality of the resin has a direct impact on the properties of the ink, as well as on the performance and visual quality of the final print.
The Challenge: Integrating a new installation into an ATEX-Certified plant
Sakata already operated an installation supplied by another manufacturer, including not only the process reactor itself but also a significant part of the associated auxiliary systems, such as pumping units, heat exchangers, pipework networks and the control system.
The new solution therefore had to be integrated into an already established production environment while providing the performance required to become a technically competitive alternative.
In addition, the project involved several key challenges:
- Executing the installation within an ATEX-classified plant.
- Designing a custom-engineered segregation system that would enable the declassification of the area affected by the new installation.
- Delivering a complete turnkey solution, including engineering, manufacturing, installation and commissioning.
- Coordinating all project phases within a demanding execution schedule without interfering with the plant’s normal operations.
Oliver + Batlle’s solution: Turnkey engineering and tailor-made ATEX safety
Installation area adaptation
To execute the project within an ATEX-classified environment, the area designated for the new reactor was segregated using custom-designed explosion-resistant panels.
This solution enabled the complete isolation of the process area and the declassification of the zone affected by the installation.
The new segregated area also incorporated:
- A continuous air renewal ventilation system.
- Dedicated lighting installations.
- Full integration with the plant’s safety requirements.
Process reactor
The core of the installation is a 6.000-litre reactor mounted on a steel platform specifically designed for the project.
Main features:
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- Nominal capacity: 6,000 litres.
- Main drive motor: 15 kW.
- Dual-arm agitation system.
- Design adapted to the specific requirements of the resin manufacturing process.
The agitation system configuration ensures homogeneous mixing and effective control throughout the different stages of the process.
Thermal control system
The reactor is equipped with a double external half-pipe jacket designed to provide precise process temperature control. These jackets are connected to chilled water, hot water and steam.
All associated utility installations were supplied and integrated by Oliver + Batlle as part of the turnkey project scope.
Prefabrication and integration of auxiliary systems
To optimise project execution times, a significant portion of the auxiliary installations was prefabricated at Oliver + Batlle’s facilities prior to shipment to the plant.
These prefabricated assemblies included process lines, utility distribution systems and auxiliary services required for resin production.
This strategy simplified installation and integration activities during the assembly phase.
Automatic cleaning system
To reduce downtime between batches, the reactor was equipped with an automatic cleaning system using self-rotating nozzles driven by the cleaning fluid itself.
This solution allows for:
- Reduced production changeover times.
- Lower manual intervention.
- Consistent and homogeneous cleaning performance.
- Increased equipment availability.
Product Transfer and Filling:
The finished product is transferred by means of a gear pump transfer unit to a filling station equipped with a 1.500 kg weighing scale.
The system enables direct filling of IBC containers, ensuring accuracy, traceability, and operational safety throughout the filling process.
Plant layout:
General View of the Installation:
Project Results
The project was successfully completed while meeting the technical, economic and scheduling objectives established by the client.
Key results achieved include:
- Completion within the planned execution schedule.
- Successful commissioning according to the established project plan.
- Delivery within the agreed budget.
- Immediate achievement of the quality parameters required by the client from the very first production batches.
- Successful integration of the new installation into the existing production environment.
- Validation of the technical solution by the Sakata INX production team.
The collaboration between Sakata INX España and Oliver + Batlle resulted in a robust solution fully adapted to the demanding requirements of resin production for the printing ink industry.
The project also demonstrated Oliver + Batlle’s capability to execute complex installations combining process engineering, ATEX compliance and equipment integration within operating industrial facilities.
A Partnership built on trust
The client’s satisfaction with the results achieved is reflected in the continued collaboration between both companies. As a sign of the confidence placed in Oliver + Batlle, Sakata INX once again entrusted the company, several years later, with the supply of a new reactor for its facilities.
Is your production plant facing ATEX safety challenges or equipment upgrades?
At Oliver + Batlle, we specialize in designing custom process engineering projects for the ink, paint, and coatings industry. We optimize your facilities through turnkey solutions to achieve maximum efficiency, safety, and profitability in your production processes.
Contact our commercial team and discover how we can help you overcome the technical challenges of your production without disrupting your normal operations.
