WHITE BASE PRODUCTION UNIT FOR PRINTING INK – PROJECT FOR SAKATA INX
1. COMPANY OVERVIEW
Sakata INX is a Japan-based multinational company and a global leader in the development and manufacture of printing inks.
Its Spanish subsidiary, Sakata INX España, S. A., operates a production facility offering a wide range of high-quality inks for the graphic sector. These products are manufactured using advanced technologies in varnish production and pigment dispersion, ensuring excellent performance and superior print quality.
The company’s commitment to innovation and continuous improvement has led it to modernise its manufacturing processes to meet the high standards of international markets.
2. PRODUCT TO BE PROCESSED
The project focused on optimising the production of a white printing ink, specifically designed for application on plastic packaging films.
This white ink acts as an opaque background layer, playing a key role in the final visual quality by enabling a clear and uniform reproduction of colours printed on top.
Due to its high opacity requirements, the formulation contains a high concentration of titanium dioxide (TiO?) — a pigment known for its covering power, but also for its high density, cost, and difficult handling properties.
3. PROJECT OBJECTIVES
Prior to implementing the new system, the unloading and dispersion of a single Big Bag of TiO? took approximately one hour, creating bottlenecks in the production line.
The client needed to significantly reduce this time without compromising product quality or operational safety.
Oliver + Batlle was tasked with developing a solution capable of:
- Increasing the speed of TiO? dosing and dispersion.
- Allowing for continuous, parallel operation to avoid production downtime.
- Improving handling safety and cleanliness.
- Maintaining or enhancing final product quality.
4. TECHNICAL SOLUTION IMPLEMENTED BU OLIVER + BATLLE
The solution integrates a high-capacity, safe and efficient powder handling system, a high-performance conical disperser, a pneumatic transfer and filtration group, and two gravimetric filling lines adapted to multiple packaging formats.
Powder handling system
- Tubular screw conveyor made of carbon steel, with discharge outlet feeding into the disperser.
- Driven by a 9.2kW motor.
- Powder handling capacity: up to 13 ?m³/h
- Three loading points:
- Two Big Bag inlets, enabling parallel operation (while one bag is being emptied, the next is positioned for uninterrupted feeding)
- One manual sack inlet, providing flexibility for smaller batches or special formulations
Dispersion systems
- POLIMIX DPS-7500-TRC conical disperser, engineered for large-scale, high-demand production
- Total capacity: 7,500 litres
- Main motor: 132 kW
- Two dispersing blades: diameters 675 mm and 450 mm
- Half-pipe cooling jacket for temperature control
- Vertical condenser with a 2 m² heat exchange surface
The disperser design ensures effective incorporation of dense pigments and a highly homogeneous mixture. Its cylindro-conical geometry optimises product flow towards the dispersing blades and improves dispersion performance.
Automatic cleaning system
- Motorised cleaning lance with rotating head
- 3″ pneumatic pump fitted with particle filter
- Nominal flow rate: 150 l/min
This system allows rapid and safe cleaning between batches, reducing downtime and avoiding cross-contamination.
Transfer and filtration
- GBN12/SBF-0102 transfer and filtration unit, pneumatically driven (2″)
- 31-litre basket filter with 200-micron mesh, ensuring product cleanliness prior to filling
Filling lines
Two gravimetric filling lines cover a wide range of formats:
1.PALLET 1500/G
- For 200-litre drums and IBCs
- Equipped with a floor scale rated up to 1,500 kg
2. OB-130
- For cans up to 30 kg
- Includes an integrated 30 kg scale
5. RESULTS ACHIEVED
The implementation of the new solution brought a significant improvement in production performance:
- Over 60% reduction in TiO? unloading and dispersion time
- Continuous operation enabled by dual Big Bag inlets, eliminating handling delays
- Increased powder flow rate, outperforming the previous system
- Higher productivity and process consistency, without compromising product quality
- Improved safety and cleanliness, through a closed and automated solution
In summary, the collaboration between Sakata Ink España and Oliver + Batlle has resulted in a robust, high-capacity and efficient installation tailored to the demanding needs of white ink production.
It is a flexible, high-performance solution that ensures top-quality standards in one of the most critical areas of the printing ink manufacturing process.
