Paint Pilot Plant: Tailored Engineering Solution

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.

Stay updated on our latest news on LinkedIn.