In a paint and resin production plant, manual valve operation was to be replaced by an automated solution. The objective was to increase process safety, standardize procedures, and restart the plant within a tight time frame – taking into account explosion-protected areas.
At a glance
- Industry: Chemical industry / paint and resin production
- Application: Automation of a paint department
- Medium / Process: Paints, resins, chemical media
- Challenge: Manual valve operation in the Ex area, high time pressure during implementation
- STASTO solution: Pneumatically actuated ball valves with explosion-protected control
- Result: Safe, automated operation and optimized production process
The challenge
In an existing production plant for paints and resins, the valve technology was predominantly implemented manually. The plant is partly located in potentially explosive areas, which imposed special requirements on components, design, and installation.
As part of maintenance and repair measures, the paint department was to be modernized while at the same time reducing the operating effort. The conversion had to be carried out within a defined time window in order to minimize downtime. Standard solutions without explosion protection or without adaptation to the existing infrastructure were not an option for this.
The STASTO solution
STASTO designed an end-to-end automation solution for the valve technology of the paint department. All existing manual valves were replaced with pneumatically actuated ball valves that are suitable for use in explosion-protected areas.
Die control was implemented via solenoid valves and control cabinets in Ex-i design, matched to the existing compressed air supply and the operational processes. The implementation was carried out in close cooperation with the operator: STASTO provided support with the design of the components, the selection of suitable designs, and the integration into the existing plant.
The focus was on a technically clean solution that could be implemented quickly, without unnecessary interventions in the overall system.
The result
By automating the valves, the paint department was able to be recommissioned as scheduled. The system now operates with a higher degree of automation and a reduced level of manual intervention.
The solution increases operational safety in the explosion-protected area, improves process stability and facilitates maintenance and switching operations during ongoing operation. In addition, a qualitative optimization of the production processes was achieved, which has a positive effect on organization and operating costs.
Added value for machine builders
- Clear, standards-compliant solution for hazardous (Ex) areas
- Easy integration into existing systems
- Reduced design and coordination effort
- High operational reliability due to pneumatic actuators
- Support for design and commissioning
This solution is particularly suitable for
- Chemical process plants
- Color and resin production
- Systems with potentially explosive atmospheres
- Modernization of existing valve technology
- Applications with high requirements for operational safety
Contact
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