CONTINUOUS PROCESS

The reality of Industry 4.0 has already reached the world of paints.
Fasten your seat belt and move into the future!

HIGH QUALITY AND LOW OPERATIONAL COST IN PRODUCTION USING CONTINUOUS PROCESS.

Increase productivity with better accuracy, less variability and in a 100% automated way.

Automatic Properties Adjustment

Automatic production system with online adjustment (control) of properties, such as:

COLOR, VISCOSITY, DENSITY, PH, CONDUCTIVITY, among others.

online quality control

Production in continuous regime, with high performance, without dead time, maximizing productivity, with total quality control online and without human interference;

less variability

Greater accuracy and less factory variability when compared to conventional technology, ensuring “source quality” for products manufactured from this technology;

Environmentally Correct

It consumes about 50% less energy to produce the same amount of product, drastically reduces the emission of solvents to the atmosphere due to the closed system, low consumption of solvent for decontamination (color change), etc .;

Make to Order

PRODUCTION UNDER DEMAND concept (make to order), reducing inventories of finished products to minimum levels;

Systems integration

Full integration with corporate systems, ERP and databases, enabling the implementation of the Industry 4.0 concept;

Intelligent retrofitting

Possibility of using existing filling machines, after retrofitting, to be incorporated directly into the process;

How the Continuous Process connects with Industry 4.0:

ONLINE
It does not require the use of materials with narrow quality ranges (colorants, resins, bases, clears, etc.), because due to online measurement and control, it adjusts properties in real time;

Production on demand, reaching the production of up to 250 batches/day (colors);

“Artificial Intelligence” algorithm (adaptive machine learning), which progressively incorporates adjustments to the original formulas, using this learning as pre-adjustments to the formulas, each time it is produced;

Liquid based color measurement system with line measurement cell (online), 100% automated, with self cleaning, self calibration, using DATACOLOR spectrophotometer and colorimetry software;

Full integration with corporate systems, ERP and databases;

Factory availability (up-time) over 95%;

Remote support for maintenance, updates, improvements;

Eliminate “human error”, due to the 100% automated process.

Industrial Automation enables real leaps in competitiveness

Advanced control strategies associated with artificial intelligence tools and 100% integrated processes guarantee optimized solutions where the business result will be maximized.

WE ARE TECH 4.0

Other benefits of Continuous Process:

We create disruptive technology that enables evolutionary leaps in the paint industry sector.

Our paradigms follow the other industrial segments that are in more advanced stages, such as the oil, petrochemical, paper and cellulose, pharmaceutical, automotive sectors, among others, where Industry 4.0 already has the necessary bases to establish itself.

Continuous Process

imagens

Continuous Process Componentes

QUICK DESCRIPTION OF OPERATION OF THE CONTINUOUS PROCESS.

The picture below shows a schematic representation of the topology of the LOW COST PAINT CONTINUOUS PROCESS.

The next picture shows the representation of the PHASE DIAGRAM of one of the “binary tanks” executing the various processes along its trajectory in its production cycle.

It is important to note that the LOW COST PAINT CONTINUOUS PROCESS, has 4 tanks (two sets of binary tanks) that perform these steps in a fully automated and synchronized way.

In a simplified way, according to the figure above, briefly, we can identify 4 distinct phases, to which each of the four cycling tanks (binary tanks) performs the production cycle, namely:

At this station, all the components of the formulation are dosed, through SMART DISPENSING MACHINE, simultaneously into the cycling tank (binary tank);

After dosing the components in the Dispensing Machine, the tank automatically moves to the Pre-Mixing station where the sealing cap automatically engages the tank, simultaneously engaging the homogenization system, when the mixing process begins period of about 2 minutes;

After completing the Pre-Mixing step, the tank automatically moves to the Adjustment and Filling Station, where its bottom valve is automatically coupled to a circulation pump.

In this station, the central element is an In-Line Mixer, which receives every load of material in adjustment.

The In-Line Mixer, in addition to the inlet valve for the material to be processed, has several additional inlet valves, for COLOR adjustment dyes, VISCOSITY adjustment solvents and still other materials intended to adjust other properties (PH, Conductivity, Coverage, etc.).

The circulation pump of this station, when starting the adjustment process, conducts the material through the In-Line Mixer and when it is expelled in its outlet pipe, it is directed to the analyzer system, circulating through these and finally led to a valve posterior directional valve, positioned to recirculate the material to the cycling tank (binary tank).

Since the In-Line Mixers have an extremely low dead volume, their residence time is of the order of 6 to 10 seconds, which makes the control action of the analyzers extremely fast.

Thus, the adjustment process, both for complex variables such as COLOR, VISCOSITY, DENSITY, among others, are very fast, occurring simultaneously in a period of 1 to 3 minutes.

 

As soon as the information from the analyzers begins to reach the PLC (Process Controller), these are processed and translated into flow rates of the adjustment material pumps, continuously changing the relationship between the flow of material in process and the flow rates of the components of adjustment, in order to achieve the specifications of the material in process.

During the stage when the computer system has not yet reached the specifications of the material in process, the flow of this material is continuously recirculated to the process tank (binary tank) that is under permanent agitation.

At the exact moment when the system reaches the product approval ranges, the directional valve posterior to the analyzers is then aligned to the filling machine, remaining in this stage until the cycling tank (binary tank) has been emptied.

After the cycling tank (binary tank) has been processed at the adjustment and filling station, the tank moves to the Cleaning station where a sealing cap automatically engages on the top of the tank, simultaneously engaging the agitation system and a discharge connector on the bottom of the tank.

The upper cap has Spray nozzles that nebulize a mixture of solvent and Nitrogen at high speed, removing all the dirt from the agitator walls and blades, while a discharge pump connected to the bottom of the tank removes the dirty solvent in this operation.

As every production cycle is very fast, about a few minutes, the paint adhered to the walls of the tank is not yet dry, making the cleaning process extremely easy.

At the end of this cycle, the tank is able to receive a new material load, automatically moving to the PHASE 1 station, as soon as the Dispensing Machine is released for a new dosage.

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Possibilidade de utilização das envazadoras existentes, após retrofitting, para se incorporarem diretamente ao processo;