{"id":23704,"date":"2026-04-09T09:44:27","date_gmt":"2026-04-09T07:44:27","guid":{"rendered":"https:\/\/oliverbatlle.com\/?p=23704"},"modified":"2026-04-09T10:02:53","modified_gmt":"2026-04-09T08:02:53","slug":"how-to-increase-paint-production-capacity-in-confined-spaces-the-alliance-maestria-case-study","status":"publish","type":"post","link":"https:\/\/oliverbatlle.com\/en\/how-to-increase-paint-production-capacity-in-confined-spaces-the-alliance-maestria-case-study\/","title":{"rendered":"How to Increase Paint Production Capacity in Confined Spaces: The Alliance Maestria Case Study"},"content":{"rendered":"<p><b>Space and headroom constraints are among the biggest challenges paint manufacturers face when trying to scale up production.<\/b><span style=\"font-weight: 400;\"> When conventional silos or hoppers simply won&#8217;t fit, manufacturers need highly customized engineering solutions that can boost output without touching the building structure. In this success story, we explore how <\/span><b>Oliver + Batlle<\/b><span style=\"font-weight: 400;\"> optimized solids feeding and pneumatic conveying for manufacturer <\/span><b>Alliance Maestria<\/b><span style=\"font-weight: 400;\">, eliminating production bottlenecks and quadrupling capacity within a severely restricted vertical space.<\/span><\/p>\n<h2><span style=\"color: #a22887;\"><b>Alliance Maestria: Innovation in Decorative Paint Manufacturing<br \/>\n<\/b><\/span><b><\/b><\/h2>\n<p><span style=\"font-weight: 400;\"><strong><a href=\"https:\/\/www.maestria.fr\/fr\/\" target=\"_blank\" rel=\"noopener\">Alliance Maestria<\/a><\/strong> is an <\/span><b>independent paint manufacturer <\/b><span style=\"font-weight: 400;\">headquartered in France, specializing in the development and production of coatings for a wide range of industrial applications. Their portfolio spans decorative solutions, flooring systems, anti-corrosion coatings, and road marking products, all formulated to meet varying regulatory and performance requirements.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">For this particular project, the scope centered on optimizing the manufacturing processes for<\/span><b> water-based decorative paints<\/b><span style=\"font-weight: 400;\">.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The product being manufactured is water-based decorative paint,a product where precise control over process conditions is critical to ensuring stability, consistency, and final quality.<\/span><\/p>\n<h2><span style=\"color: #a22887;\"><b>The Challenge: Maximizing Solids Discharge in a Constrained Vertical Space<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">The primary technical constraint was the limited headroom in the dispersion area, which ruled out the use of conventional large-volume solids discharge hoppers.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">This meant rethinking the entire raw material feeding system from scratch, finding a compact vertical solution that wouldn&#8217;t compromise process performance.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Alongside this, production requirements demanded high discharge flow rates in line with contractually agreed targets:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Carbonates<\/b><span style=\"font-weight: 400;\">: 15\u201318 t\/h\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Titanium dioxide (TiO2<\/b><b>)<\/b><span style=\"font-weight: 400;\">: 10\u201312 t\/h\u00a0<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">The technical challenge was therefore to engineer a dosing system that could perform within highly restricted spatial conditions, matching or exceeding the feed rates of conventional hoppers while delivering continuous, stable, and controlled solids discharge.<\/span><\/p>\n<h2><span style=\"color: #a22887;\"><b>The Oliver + Batlle Solution: Integrated Automation and Pneumatic Conveying<br \/>\n<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\"><a href=\"https:\/\/oliverbatlle.com\/en\/\" target=\"_blank\" rel=\"noopener\"><strong>Oliver + Batlle<\/strong><\/a> designed and implemented a <\/span><b>comprehensive engineering solution<\/b><span style=\"font-weight: 400;\"> aimed at making the most of the available space while fully meeting production requirements. The solution brings together solids handling, liquid dosing, dispersion, and packaging systems \u2014 all integrated under a single framework of<\/span><b> advanced automation.<\/b><\/p>\n<h3><b>High-Efficiency Cyclonic Hopper System<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Two cyclonic hoppers (<\/span><b>SH-01 and SH-02)<\/b><span style=\"font-weight: 400;\"> were installed at the highest available elevation, making full use of the vertical space. These hoppers deliver continuous, controlled solids discharge directly onto the dispersers:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><a href=\"https:\/\/oliverbatlle.com\/en\/prod\/mixing-equipment-polimix-dps\/\" target=\"_blank\" rel=\"noopener\"><b>Polimix DPS 5000\u00a0\u00a0<\/b><\/a><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><a href=\"https:\/\/oliverbatlle.com\/en\/prod\/mixing-equipment-polimix-dps-or\/\" target=\"_blank\" rel=\"noopener\"><b>Polimix DPS-8000-ORC<\/b><\/a><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">The cyclonic geometry promotes the flow of cohesive materials, minimizing bridging and caking risks while sustaining continuous, high-rate discharge in space-constrained conditions.<\/span><\/p>\n<p><img fetchpriority=\"high\" decoding=\"async\" class=\"aligncenter wp-image-23707 size-full\" src=\"https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/04\/Imagen1-ALLIANCE-MAESTRIA.png\" alt=\"\" width=\"680\" height=\"439\" srcset=\"https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/04\/Imagen1-ALLIANCE-MAESTRIA.png 680w, https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/04\/Imagen1-ALLIANCE-MAESTRIA-300x194.png 300w\" sizes=\"(max-width: 680px) 100vw, 680px\" \/><\/p>\n<h3><\/h3>\n<h3><b>Closed-Loop Pneumatic Conveying (<\/b><b><i>Loop System<\/i><\/b><b>)\u00a0<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">Solids transfer relies on<\/span><b> dilute-phase pneumatic conveying<\/b><span style=\"font-weight: 400;\"> in a closed-loop configuration, moving material from 14 m\u00b3 floor-level storage hoppers (WH-01 and WH-02) up to the cyclonic hoppers.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">This design delivers:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Zero dust emissions<\/b><span style=\"font-weight: 400;\">: the system is fully enclosed\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Improved safety and housekeeping conditions\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Continuous, stable feed to the dispersers<\/span><\/span><\/li>\n<\/ul>\n<h3><b>Precise Liquid Additive and Emulsion Dosing<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">A dedicated system was put in place to handle liquid additives and emulsions, built around <\/span><b>250 L weighing hoppers<\/b><span style=\"font-weight: 400;\"> and automatic distribution manifolds.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">This system enables:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Precise, repeatable dosing of critical components\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Flexible feeding to both dispersers and finishing tanks\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\"><span style=\"font-weight: 400;\">Full integration into the process control logic<\/span><\/span><img decoding=\"async\" class=\"size-full wp-image-23710 aligncenter\" src=\"https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/04\/Imagen2-ALLIANCE-MAESTRIA.png\" alt=\"\" width=\"680\" height=\"371\" srcset=\"https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/04\/Imagen2-ALLIANCE-MAESTRIA.png 680w, https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/04\/Imagen2-ALLIANCE-MAESTRIA-300x164.png 300w\" sizes=\"(max-width: 680px) 100vw, 680px\" \/><\/li>\n<\/ul>\n<h3><b>100% Automated Finishing and Packaging Lines<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">The installation is rounded out by a system for<\/span><b> fully automated product finishing and conditioning:<\/b><\/p>\n<p><b>Finishing tanks:<\/b><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">4 units of 16,000 L\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">2 units of 11,000 L\u00a0<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Fitted with high-precision Mettler Toledo weighing systems and CIP cleaning via rotary spray heads.<\/span><\/p>\n<p><b>Packaging lines:<\/b><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">Two automatic volumetric filling lines, <\/span><a href=\"https:\/\/oliverbatlle.com\/en\/prod\/volumetric-filling-equipment-flash-21\/\" target=\"_blank\" rel=\"noopener\"><b>Flash 21<\/b><\/a><span style=\"font-weight: 400;\">, designed for precision, repeatability, and high production throughput.<\/span><\/p>\n<h3><b>Operational and Safety Improvements<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">In a subsequent project phase, further upgrades were introduced to boost system reliability and working conditions:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Replacement of vibration-based systems with <\/span><b>Airsweep technology<\/b><span style=\"font-weight: 400;\"> to improve solids discharge in large-volume hoppers\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Automation of packaging line cleaning cycles using dedicated Siemens S7-1200 PLCs\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">Installation of a Big-Bag handling system with a<\/span><b> 2,000 kg hoist, <\/b><span style=\"font-weight: 400;\">improving ergonomics and reducing operational hazards<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Together, these improvements <\/span><b>eliminated the constraints of the previous system <\/b><span style=\"font-weight: 400;\">and established a robust operational foundation capable of meeting , and exceeding, the flow rate and productivity targets defined in the project.<\/span><\/p>\n<h2><span style=\"color: #a22887;\"><b>Arc-En-Ciel Project Results: Greater Profitability and a Cleaner Plant<br \/>\n<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">The implementation of the <\/span><i><span style=\"font-weight: 400;\">Arc-En-Ciel<\/span><\/i><span style=\"font-weight: 400;\"> project has delivered a significant step forward in operational performance, particularly in terms of <\/span><b>conveying capacity, cycle time reduction, and overall process efficiency<\/b><span style=\"font-weight: 400;\">.<\/span><\/p>\n<h3><b>Significant Increase in Conveying Flow Rates<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">The closed-loop pneumatic conveying system, combined with the cyclonic hoppers, has not only met but surpassed the contractual targets:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Calcium carbonate (CaCO3<\/b><b>)<\/b><span style=\"font-weight: 400;\">: hasta 20 t\/h (objetivo: 18 t\/h)\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Titanium dioxide (TiO2<\/b><b>)<\/b><span style=\"font-weight: 400;\">: hasta 17 t\/h (objetivo: 12 t\/h)\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Talc<\/b><span style=\"font-weight: 400;\">: up to 11 t\/h\u00a0<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">These figures represent a substantial improvement over the previous system, eliminating the bottlenecks caused by poor solid-air separation that had been restricting flow rates and causing material losses.<\/span><\/p>\n<h3><b>Reduced Cycle Times and Higher Productivity<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">The higher feed rates have made it possible to<\/span><b> quadruple solids feeding capacity<\/b><span style=\"font-weight: 400;\"> to the dispersion stage, significantly cutting batch loading times and, by extension, total process time.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The knock-on effects are tangible:<\/span><\/p>\n<ul>\n<li aria-level=\"1\"><b>Higher plant throughput\u00a0<\/b><\/li>\n<li aria-level=\"1\"><b>Less idle time<\/b><span style=\"font-weight: 400;\"> in the dispersion stage\u00a0<\/span><\/li>\n<li aria-level=\"1\"><b>Improved overall equipment effectiveness<\/b><span style=\"font-weight: 400;\"> (OEE)<\/span><\/li>\n<\/ul>\n<h3><\/h3>\n<h3><b>Better Product Containment and Working Conditions<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">The switch to a closed-loop conveying system <\/span><b>has eliminated dust emissions<\/b><span style=\"font-weight: 400;\"> and the material losses associated with traditional filtration-based systems.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">On top of this, integrating <\/span><a href=\"https:\/\/oliverbatlle.com\/en\/pipeline-cleaning-system-for-paint-factories\/\" target=\"_blank\" rel=\"noopener\"><b>pigging <\/b><\/a><span style=\"font-weight: 400;\">(pipe cleaning)<\/span><span style=\"font-weight: 400;\"> transfer systems on the mill-base lines has made it possible to:<\/span><\/p>\n<ul>\n<li><span style=\"font-weight: 400;\">Maximize product recovery\u00a0<\/span><\/li>\n<li aria-level=\"1\"><b>Reduce waste\u00a0<\/b><\/li>\n<li aria-level=\"1\"><span style=\"font-weight: 400;\">Improve cleaning efficiency and process traceability<\/span><\/li>\n<\/ul>\n<h3><b>Expanded Parallel Operating Capacity<\/b><\/h3>\n<p><span style=\"font-weight: 400;\">The system architecture \u2014 with independent conveying lines including duplicated storage hoppers, blowers, and cyclonic hoppers \u2014 enables<\/span><b> simultaneous feeding of two dispersers,<\/b><span style=\"font-weight: 400;\"> effectively doubling the plant&#8217;s operational capacity at the solids loading stage.<\/span><\/p>\n<h2><span style=\"color: #a22887;\"><b>Technical Assessment: Eliminating Manufacturing Bottlenecks<\/b><\/span><\/h2>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Elimination of the main process bottleneck<\/b><span style=\"font-weight: 400;\"> (solids feeding)\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Simultaneous improvement<\/b><span style=\"font-weight: 400;\"> across capacity, operational efficiency, and cleanliness <\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>A step change <\/b>from a design-limited system to a robust, scalable solution fit for demanding production environments<\/li>\n<\/ul>\n<h2><span style=\"color: #a22887;\"><b>Is your production plant facing space or capacity challenges?<\/b><\/span><\/h2>\n<p><span style=\"font-weight: 400;\">At Oliver + Batlle, we specialize in designing bespoke <\/span><a href=\"https:\/\/oliverbatlle.com\/en\/process-engineering\/\" target=\"_blank\" rel=\"noopener\"><b>process engineering<\/b><\/a><span style=\"font-weight: 400;\">\u00a0projects for the paint and coatings industry. We optimize your facilities to achieve maximum efficiency and profitability.\u00a0<\/span><\/p>\n<p><a href=\"https:\/\/oliverbatlle.com\/en\/contact\/\" target=\"_blank\" rel=\"noopener\"><span style=\"font-weight: 400;\">Get in touch with our engineering team today<\/span><\/a> <span style=\"font-weight: 400;\">and find out how we can help you overcome your production bottlenecks.<\/span><\/p>\n<p><a href=\"https:\/\/www.linkedin.com\/company\/oliver-batlle-s-a-\/\" target=\"_blank\" rel=\"noopener\"><img decoding=\"async\" class=\"alignnone size-full wp-image-23637\" src=\"https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/03\/2-1.png\" alt=\"\" width=\"1600\" height=\"600\" srcset=\"https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/03\/2-1.png 1600w, https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/03\/2-1-300x113.png 300w, https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/03\/2-1-1030x386.png 1030w, https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/03\/2-1-768x288.png 768w, https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/03\/2-1-1536x576.png 1536w, https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/03\/2-1-1500x563.png 1500w, https:\/\/oliverbatlle.com\/wp-content\/uploads\/2026\/03\/2-1-705x264.png 705w\" sizes=\"(max-width: 1600px) 100vw, 1600px\" \/><\/a><\/p>\n\n\t\t\t<div\n\t\t\tclass=\"hs-form-frame\"\n\t\t\tdata-region=\"eu1\"\n\t\t\tdata-form-id=\"318b29b5-e207-4d3e-912d-1102a4a108e7\"\n\t\t\tdata-portal-id=\"147556243\"\n\t\t\t >\n\t\t\t<\/div>\n\t\t\t\n","protected":false},"excerpt":{"rendered":"<p>Space and headroom constraints are among the biggest challenges paint manufacturers face when trying to scale up production. When conventional silos or hoppers simply won&#8217;t fit, manufacturers need highly customized engineering solutions that can boost output without touching the building structure. In this success story, we explore how Oliver + Batlle optimized solids feeding and [&hellip;]<\/p>\n","protected":false},"author":15,"featured_media":23749,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"content-type":"","footnotes":""},"categories":[50518882,50518885,50518883,50518886],"tags":[50519147,50519148,50519150,50519149],"class_list":["post-23704","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog-en","category-filling-palletizing","category-mixing","category-process","tag-alliance-maestria","tag-case-study","tag-coatings-en","tag-oliverbatlle-en"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v25.1 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>How to Increase Paint Production Capacity: Maestria Case Study<\/title>\n<meta name=\"description\" content=\"Discover how Alliance Maestria quadrupled paint production in confined spaces by 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