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Monday, 14 October 2019
Events, EC Technology Forum | Optimising cost and processes in paint formulation, Conference Programme

Abstracts

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Transition from conventional to modern coating manufacturing processes

Frank Kother, TMC

Systematic change from traditional formulations concepts towards modern modular based working procedures is the challenge in modernizing processes in inks and coatings manufacturing. Change management and consistent review of those in the production of coatings and inks is often done by increasing the capacities with the need of a detailed planning based on market data. In the lecture the whole process from market data collection and evaluation, project descriptions and execution will be presented and opening the discussion on that.  The needed change in the formulation structure provides possibilities to reduce process costs and become highly more competitive. Various examples will be shown and of continuous change in the coatings industry, necessary steps will be shown to control costs and improve competitiveness in future.

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Expectations, possibilities and limitations by using modular production technology

Dr Markus Boos, Remmers

Remmers had high expectations at the beginning of the work on the use of modular production-technology in the area of paint producing. Some of them were fulfilled, others turned out to be too overoptimistic. The aim of the lecture is to show the experiences gained by switching from a "conventional” production method to the "new” dispersion and mixing technology by using modular formulations.

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Additives in modern production processes

Markus Vogel, Evonik Resource Efficiency

Continuous production methods offer the chance to increase efficiency. Going along with this, significantly changing processes might result in the need to adjust formulations. This can of course also be true for additive packages. The right defoamer e.g. is usually picked to match the needed balance of defoaming efficiency & compatibility – which significantly depends on shear forces during incorporation. So adjustment of defoamers to more compatible products is one option. With respect to particle wetting, grinding & stabilization a change in process can be a reason to optimize the initial replacement of air on the pigment surface e.g. by using specialty surfactants or to optimize intermediate stabilization (till high molecular weight dispersants fully cover the surface area). Last but not least more modular production concepts will put an extra importance on broad compatibility & applicability of the raw materials used.

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Rheological additives – their use in modern production process

Detlef van Pey

Presentation will provide some insight how to use rheological additives in modern paints & coatings in optimised production processes. Beside the required flow behaviour the requirement of pre-gels will be discussed.

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Optimising paints and coatings through a more detailed cooperation of paint producers and raw material manufacturers

Markus Dimmers, Alberdingk Boley

Today’s world of paint and coating formulation is getting more complex every day. Raw material shortages, new regulations and the wish for a higher product performance drive the whole industry.  Instead of using only the paint producers know how and equipment/ analytics we would like to discuss ways to utilising the comprehensive know how of the raw material suppliers and their equipment to increase speed in development and to drastically improve properties. This means that an open and trustful cooperation is required for the benefit of all parties.

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Predictive sciences and high throughput screening combined for efficient coating developments

Sander van Loon, VLCI

The applied predictive formulation sciences, Hansen Solubility Parameters (HSP) and Hydrophilic Lipophilic Difference – Net Average Curvature (HLD-NAC) are very powerful to find matching ingredients, resulting in improved stability and efficacy of end-products. The models are applicable to solutions, dispersions and emulsions, which basically includes all types of formulations. Although they have been applied for many years, there is still a limited use, especially in coating developments and ingredients thereof. The equations of these sciences require (practical) parameters of the ingredients and once generated, compatible ingredients can be predicted to develop and optimize specific formulations. The ingredient data generated from these models is predictive and sustainable: you can use them over and over, allowing to move away from trial-and-error and improve digitalization into product developments. A very efficient way to enhance the properties and reduce complexity, time and cost in the development of coatings or ingredients. When combined with High Throughput (HT) screening for automated, parallel and small-scale preparation of samples and coatings, further efficiency can be achieved. The predictive sciences, their practical applications and the combined approach with HT will be discussed during this section of the workshop.

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Optimization of paints & inks production processes with the combination of the inline-disperser EPSILON and the new agitated media mills Discus and NEOS

Dr Alex Lauke, Netzsch-Feinmahltechnik

For Global Paint & Ink producers it is a common target to achieve a constant high product quality – taking into consideration that production sites are spread globally. This target is sometimes challenging since raw material quality differs from region to region – at the same time processing equipment and process design often differs from production site to production site. As a trend paint & ink producers are using smaller grinding media within the grinding step in order to improve ink quality such as color strength, transparency and gloss. Furthermore the use of smaller grinding media often reduces milling time and saves pigments - the latter being the major cost factor within the ink production. When using smaller grinding media it is essential to guarantee an efficient pre mixing of the mill base in order to achieve a smooth milling step without any high pressure or even clogging of the mill. For the pre mixing step Netzsch offers the Inline-Disperser Epsilon. The Epsilon is designed with a rotor that provides strong vacuum, high flow rates and a decent shearing of the slurry. Furthermore the Epsilon is equipped with a powder intake. The Epsilon rotor that is equipped with spiral wound racks provides an efficient wetting of the premix. Due to the powder intake by the Epsilon there will no dry pigment that sticks to the inner wall of the mixing tank – which makes it easy to clean. Since the gaps within the Epsilon process chamber are slightly larger compared to a standard rotor stator system the Epsilon undergoes only little wear and tear – the pre-mix quality is always on the same high quality level. For the fine grinding step Netzsch offers the new agitated media mills Discus and Neos: ·  The new pin type mill "Neos” is designed for running with small grinding media in recirculation mode at highest flow rates. The ceramic made mill chamber provides low product temperatures and a long machine life time. ·  The new disc type mill "Discus” is designed for preferable single pass operation. The new intensive rotor provides a high milling efficiency and a high flow stability. The Discus is equipped with a ceramic liner – same like the Neos – that provides low product temperatures and a long machine life time. The presentation describes the process concept based on Epsilon and Discus/Neos and also explains the design of the single components.

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New ways of paint production using liquid modules of solid ingredients – paint manufacturing 4.0

Dr Uwe Wilkenhöhner, Kronos Titan

Today, manufacturing principles based on  modular production strategies are established in many different industries. The advanced automotive industry is a representative example. Such industries have organized their productions based on supplier integrations using also pre-assembled modules. With few exceptions, the paint manufacturing industry still operates industrial production in a very conservative way. Singular raw material handling steps and sequential dosing of various feeds, processed by high-speed dispersion units, are still common manufacturing practice. A typical architectural paint formulation contains multiple different raw materials from various suppliers and requires  high logistics efforts for internal  handling and in addition particularly stock-keeping. Depending on the batch size, degree of automatization and existing infrastructure (piping, silo or bag handling etc.), the effective time for production of a paint batch is significant and largely exceeds the time that is needed to disperse the powder raw materials in the dispersing unit. The process of charging the production vessel with the powders only can exceed the time needed for dispersing them. The latter can , depending on the desired quality, also be time- and energy-consuming production steps. Omya and KRONOS provide inorganic ingredients based on mineral extenders and Titanium Dioxide which are indispensable for state of the art paint formulations. Both companies have decided to enter a partnership and to join forces for the development of a new generation of liquid modules to optimize processes of paint production. These liquid modules use the synergies of high-quality raw materials of both companies, are perfectly dispersed and stabilized to offer the best performance for the formulation of architectural and industrial waterborne paints.

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Solvent-free, dust-free, easy-to-handle – metallic pigment concentrates

Dr Andrea Fetz, Eckart

Sustainability and efficiency are the keywords today. VOC regulations and easy handling play an important role in the paint industry. Concentrates -  solvent-free preparations, instant powders or pumpable dispersions are examples for different dosage forms of metallic pigments and offer solutions for various applications. New test methods increase efficiency and continuity in quality control.

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Concepts and economics for in-plant tinting solutions

Dr Gerard van Zijl, Chromaflo Technologies Europe

Chromaflo Technologies understands that paint manufacturers are seeking economical and accurate in-plant tinting solutions to provide a wide color variety for ready mix lines. A well designed in-plant system should yield a net gain in the overall manufacturing process. Chromaflo Technologies will present concepts for economic in-plant tinting systems and can assist in identifying the cost benefits related to that choice.

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Silica slurries for coating applications

Dr Alexander Kröger, Grace 

Matt surface finishes are enjoying ever growing popularity. The wood and metal coating markets display a growing tendency towards deep-matt surfaces. Micronized silica is and has been the prime matting technology for matting of surface coatings. The matting efficiency of silica is controlled by a variety of parameters including particle size and pore volume. Silica intermediates exhibit significant advantages over the powdered products. Production time is reduced by up to 80 %, the quality is consistent and verifiable, the slurries can be post added and dust and foaming is kept at a minimum. Due to the unique surface structure, silica slurry formulation is not as straightforward as other filler slurries. Contrary to common expectations, the matting efficiency of a slurry often deviates from the efficiency of the powdered material. The choice of additives is impacts dispersion state, slurry stability, the matting effect and the impact on the chemical resistance of the coating.

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Process simulation - identification of bottle necks and options to improve productivity in coatings production

Dr Martin Breucker 

Processes in paint production tend to be fairly complex both with regard to the various process steps and the product portfolio and in addition are subject to variations driven by raw material batch properties, process reliability and operator behavior. Production volumes are often product dependent and require different times for loading, processing and filling. This can include differences in transport times (distance to warehouses for liquid vs. solid RMs, fork truck vs. fixed pipes), impacts from the logistics of packaging of both RMs and finished product (big bags vs. pails, can sizes, bulk shipments, etc.). The need for cleaning cycles might be determined by the sequence of products and affects the availability of resources (like operators, dissolvers, mills, drums, etc.). The ability to store/buffer semi-finished, finished products and intermediates is often limited by the available space or safety requirements. The use of certain machinery or equipment can even be restricted to specific time windows due to noise considerations. And every once in while operators go on vacation and there is maintenance needed for the machinery. All these limitations, variabilities and mutual dependencies create a very complex scenario. It is therefore a non-trivial task to assess the real process capacity and options for improvements through adjusted man power, asset investments or changes in the product portfolio – "linear” models like a spread sheet typically cannot reflect this complexity. The talk demonstrates the use of a computer-based process simulation tool based on real production situations to analyze processes and identify options for improvements.

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Design of experiments for high-throughput screening

Dr Christian Schmitz, Hochschule Niederrhein ILOC

The high-throughput screening technology can accelerate the development of new coating products due to a faster automated lab process for the preparation of samples and characterization of its properties. Since the outcome of the daily work is being increased, the experiments need to be planned well ("good data") for the statistical analysis, which is called Design of Experiments (DoE). The DoE will reveal how the properties/characteristics of the coating is influenced by the input variable (e.g. concentration of ingredients, process parameters). Finally, this information will help to predict and/or optimize the properties of a product.

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Thinking outside the box - How inline dispersing is revolutionising processes in the coatings industry

Hans-Joachim Jacob, Ystral

Whether you manufacture decorative paints, industrial coatings, coil coatings, automotive lacquers, printing inks or even adhesives, large amounts of powders have to be dispersed into liquids. In most cases, this process requires high effort, it is time consuming and usually dusty… In order to efficiently disperse powders into liquids, it is necessary to integrate plural process steps which are typically carried out successively. Individual subprocesses are not to be executed in parallel or sequentially but integrated and concurrently. With process systems based on the inline dispersing technology a higher efficiency incorporation of the raw materials and a better quality of the products are proven. This also offers the opportunity to develop processes which allow semi-continuous to continuous manufacturing of paints and coatings.

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Material cost is only half the truth

Hendrik Hustert, Orontec

Material performance influences process cycle time, correction cycles and delivery time. High process performance needs to be target of the development to provide formulations with high production effficiency. Transfer into a production scale should include process controls from the beginning to avoid variation propagation as early as possible. Q-Chain Process AI and Liquid Color Measurement are two examples how to evaluate data and use it along the value stream chain.

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tbc

Alexander Böhler, Cellfacts

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Contact

Bettina Hoffmann
Bettina Hoffmann
Senior Event Manager
Vincentz Network
+49 511 99 10 271
+49 511 99 10 279

Conference Programme

Conference Programme
Conference Programme
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