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Paint and coatings

manufacturing
Creating value through integrated solutions
2 3

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ABB has developped solutions and engineering
services for the paint and coating manufacturing
processes, including design, installation, commis-
sioning of automated paint production plants.
4 PA I N T A N D C O AT I N G S I N D U S T R Y C R E AT I N G VA LU E T H R O U G H I N T E G R AT E D S O LU T I O N S PROCESS ENGINEERING 5

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Process engineering

Paint and coating applications Technology portfolio Process control/automation ABB offer a global solution supported by:
ABB design and supply turnkey production units Using its process expertise and experience in Based on specific referenced paint software
for the following paint and coating paint and coating production, ABB has developed developed for this market, ABB designs and • a project management focused organization,
applications: innovative and optimized solutions for the key implements the plant automation from the • process specialists,
paint production phases: powder handling, definition of specifications to the start-up of the • efficient engineering and design departments,
• decorative paints (water- and solvent-based), transfer and pigging, metering and dosing, dis- unit. ABB team is composed of paint process • innovative products and technologies,
• industrial paints, persing and mixing, filtration, cleaning in place, experts and automation engineers bringing • worldwide sales and service network,
• automotive paints, production management and scheduling. solutions and anticipating your needs in terms • the ABB global structure.
• marine paints, ABB has extensive experience in integrating tech- of computer management of formula, recipes,
• coil coatings, nologies developed by reliable partners for grind- traceability, scheduling, etc.
• etc. ing, tinting, filling and palletizing.

Our expertise extends to resins, glues, adhesives,

compounds, inks, gelcoats and sealants.

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In the range and scope of its
technologies, systems and
services, ABB will bring you
customized solutions for a
successful investment.

Process specialists
Combining the mastering of production
processes and operating phases with its market
knowledge, ABB has been involved in the develop-
ment of international paint manufacturers. ABB
paint process experts are aware of your market
and production constraints. ABB has been
designing and engineering original solutions for
paint and coating production plants for more
than 30 years.

Service and expertise for a global solution

With a real knowledge of your business, ABB are
the ideal partner able to manage the project from
the feasibility study, basic engineering and detail
design up to the delivery, start-up and operators
training of the turnkey plant. ABB will help you to
optimize your project at all levels, whatever its
size and specific requirements.
6 PA I N T A N D C O AT I N G S I N D U S T R Y C R E AT I N G VA LU E T H R O U G H I N T E G R AT E D S O LU T I O N S I N N O VAT I V E A N D D E D I C AT E D T E C H N O LO G I E S 7

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Innovative and dedicated technologies

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01 In-Line
dispersing unit with
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control system
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02 Conical bottoms
Optimised production performance
of dual-shaft
dispersers with finished
product transfer
through pigged lines With innovative and dedicated solutions, ABB Delicel™: dual-shaft conical disperser
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03 Series of Clean- design and install customized units to meet • wide product range (high solid content,
In-Place Delicel™ your needs: viscosity)
• streamline your production process • high dispersing fineness
• design modular workshops • high pumping rate of viscous products
• implement in-line systems • excellent productivity
• batch size flexibility
ABB has developped mixing and dispersing • integrated cleaning devices
units specially to meet the paint and coating
manufacturing requirements: In-line dispersing unit
• high process flexibility
• high quality dispersion
— • automated process with embedded
01
control system —
• compact and skidded unit 03
• complicance with HSE standards
• cost savings

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02

Meet and increase production Reduced raw materials

capacity consumption

• Shorter and improved cycle • High dosing accuracy to meet

times right first time requirement
• Controlled accuracy & • Reduced inventory and need
repeatability for storage tanks
• Increase throughput

Manpower savings Increased energy efficiency

• Automated dosing, mixing • Reduced power consumption

and cleaning thanks to well dimensioned
• Reduced need for manual motors equipped with fre-
intervention and analysis quency inverters and inte-
grated control.
8 PA I N T A N D C O AT I N G S I N D U S T R Y C R E AT I N G VA LU E T H R O U G H I N T E G R AT E D S O LU T I O N S 9

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Piggable transfer lines at every process steps
ABB propose the pigging technology at every process
step for the transfer of liquid raw materials, semi-
finished products from disperser to let-down tanks
and finished products to filling units.
10 PA I N T A N D C O AT I N G S I N D U S T R Y C R E AT I N G VA LU E T H R O U G H I N T E G R AT E D S O LU T I O N S G R E E N E R A N D S A F E R M A N U FA C T U R I N G U N I T S 11

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03

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Greener and safer manufacturing units

— Powder handling Clean-In-Place (CIP) solutions Pipe pigging

01 Powder silos
— Implementation of dosing, handling and pneu- As part of an optimised plant design, ABB has Thanks to the development of its components
02 Top of powder silos matic transfer solutions to drastically reduce developed innovative cleaning in place systems (multi-way valves, manifold, etc), the pipe pigging
fed through pneumatic
transport pipes dust, improve accuracy and save manpower when dedicated to the paint and coating industry. technology has become a real process tool flexi-
— handling powders, such as: bilising the whole production unit:
03 Piggable collec-
tor to precisely dose In-line filter with integrated cleaning system:
liquid materials through • titanium dioxide • no product cross-contamination
massflowmeters
— • calcium carbonate • efficient filtration with limited pressure drop • minimal waste generation
04 Pig used for multiple • talc • automatic declogging and self-cleaning • robust design and low maintenance
product transfers
through one line • silica, aerosil, sequence • attractive payback
• barium sulphate, • optimised cleaning time • easy layout and modularity
• etc. • low product losses

High-efficiency cleaning system for dispersers:

Safe process and workplaces
• high and medium pressure systems
— • Automated systems
01 • automatic and repeatable cleaning
• Closed circuits
• controlled consumption and recycling of
• Dust reduction
cleaning media
• Reduced VOC exposure

Reduced material losses

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—
• Accurate dosing 04
02 • Elimination of dosing errors
• No cross-contamination

Increased flexibility

• Fast production changes

• Better equipment allocation
• De-bottlenecking

Optimized cleaning and better

effluent management

• Cleanliness
• Reduction of effluents and
cleaning products
• Recycling of raw materials
and cleaning products
12 PA I N T A N D C O AT I N G S I N D U S T R Y C R E AT I N G VA LU E T H R O U G H I N T E G R AT E D S O LU T I O N S 13

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Your process under control
ABB paint process experts and automation
engineers have developed Paintcel™, a
powerful control system for batch production
monitoring and management which perfectly
fits the requirements of paint manufacturers.

Paintcel™ ensures the entire management

of raw materials, product formulation, sub-
recipes and recipes, inventories, production
and cleaning sequences. Parameter setting
enables Paintcel™ to optimize the production.
Paintcel™ is a plant-wide control svystem
integrating sub-systems such as PLCs,
controllers, MMIs. It has not limits in
communicating with other systems such as
lab or business sytems (ERP).

The scheduling function of Paintcel™ enables

the management of individual unit
operations. It integrates the minimisation of
effluent generation, management of
resources, equipment occupancy rate and
packaging units.
14 PA I N T A N D C O AT I N G S I N D U S T R Y C R E AT I N G VA LU E T H R O U G H I N T E G R AT E D S O LU T I O N S F U L LY A U TO M AT E D P L A N T S 15

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Fully automated plants

— Paintcel™ is a powerful control system for batch bilities, warehouse management, advanced Enhanced productivity Optimised equipment
01 Paintcel™ screens
with data base or in-line production monitoring and manage- schedule features. It has no limits in communi- availability and resources
and synoptics ment which perfectly fits the requirements of cating with other systems such as lab or business • Produce on-spec with • Management of equipment
—
02 Filling lines inter- paint and coatings manufacturers. Paintcel™ systems (ERP). more process flexibility and tank status
faced with Paintcel™ ensures the entire management of raw materials, • Real-time monitoring and • Safe startups and shutdowns
control system
product formulation, sub-recipes and recipes, Paintcel™ is able to be integrated with the major- tuning • Management of assets with
resources, inventories, production batches and ity of PLCs or controllers. With Paintcel™ you will • Management of KPIs predictive maintenance
cleaning sequences. Parameter setting enables achieve the total process control and plant sched-
Paintcel™ to optimize the production. uling software integration of your production
Recipe management and High connectivity control
system.
complete traceability system
Paintcel™ can be extended to encompass the
control and supervision of all the operations • Safe product changes • Integrated and scalable
within the plant, from raw material reception and • Repeatability of recipes architecture
storage to product dispatch (blending, interme- • Record of lab results • Interfaceability with ERP, lab,
diate storage, transfers, filling and warehouse). • Prevent from cross- warehouse, ... systems
It is a plant-wide control system integrating contaminations • Reports and analytics
sub-systems such as graphics, workshop capa-
— —
01 02
16 PA I N T A N D C O AT I N G S I N D U S T R Y C R E AT I N G VA LU E T H R O U G H I N T E G R AT E D S O LU T I O N S 17

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Performance Improvement
We know how to provide world class services
anywhere, anytime when you need assistance
to improve the reliability, availability,
maintainability, productivity and safety of
your equipment and production processes.

Our service portfolio includes engineering

and consulting, maintenance, advanced
services and IT tools, extensions, upgrades
and retrofits, training as well as service
agreements.

Thanks to dedicated specialists, you get fast

issue resolution and local support at the
right time.
18 PA I N T A N D C O AT I N G S I N D U S T R Y C R E AT I N G VA LU E T H R O U G H I N T E G R AT E D S O LU T I O N S YOUR PE RFORMA NCE IS OUR CONCE RN 19

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Your performance is our concern

— Our process team will: Based on our process engineering expertise and
01 3-D model review
conducted with the • evaluate your process experience, ABB design and develop innovative
customer to ensure that • analyse (with you) how to get the best return on solutions, especially dedicated to the paint and
the plant comply with
project requirements investment coating industry:
— • bring you operational ideas and techniques for • original solutions and systems cleaning
02 Let-down tanks
served by pigged lines your plant • solutions for production organisation
— • optimize the operation and investment global • new designs of modular workshops, in-line sys-
03 Storage tanks
in Atex area with cost, while reducing operating maintenance tems, etc.
— —
operator terminal • design a flexible and evoluting production plant 02 03
• design equipment matching your real needs Our engineers will study how to optimize and
• analyze cost benefit improve your production performances:
• offer quality and reliable solutions • quality at the right price
Decrease of ABB will find the right solutions to reduce
• propose unit simulation and trials • just in time distribution manufacturing
material losses adjustments, increase production and ensure
• offer complete structured service from au- • direct savings on your paint production
product consistency:
dit-expertise to staff training • reactivity of your production
• full recipe management with complete
• anticipate your requirements and create innova- Storage
traceability
tive solutions Our concern for health and environment protec- optimisation
• optimization of equipment use: dispersers,
tion leads us to develop original solutions to:
letdown tanks, grinding mills, filling and
• reduce effluent generation
palletising lines, etc.
— • reduce volatile organic compounds (VOC)
• optimize the cleaning and recycling
We will evaluate your needs and • implement safe processes and working condi-
From consulting to life-cycle management
ABB offer a full range of dedicated services to
the requirements to reach sus- tions
reach an optimized operational paint plant.
tainable development. We help • work in closed systems Reduction of Benefits resulting
you to prepare the future.
maintenance/ from workshop Design and validation
staff costs • basic engineering
revamping • tests of solutions
• process improvements
— • plant simulation
01

Project execution
• detailed studies
Reduction • procurement and construction
of effluents Right First
• site activities
Time ratio
• commissioning and start-up
improvement
Completion and evolution
• educational services
• maintenance
• plant evolution and revamping
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ABB France
Industrial Automation Division
Cellier Activity
700 boulevard Jean-Jules Herbert
Parc d'Activités des Combaruches
73100 Aix-Les-Bains, France
Tel. : +33 4 79 35 05 65
E-mail: info.cellier@fr.abb.com

Contact for the U.S.A.:

Tel. : +1 832 421 4864
E-mail: pablo.e.garce@us.abb.com

abb.com/chemical

Additional information
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changes or modify the contents of this
document without prior notice. With
regard to purchase orders, the agreed
particulars shall prevail. ABB AG does
not accept any responsibility whatso-
ever for potential errors or possible lack
of information in this document.
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