For the construction of a new production hall for paint manufacturing, the entire required valve range was to be supplied from a single source. The system includes transfer lines for dissolvers and mixers as well as a tank installation. Solvent-based, binder-rich and water-based paints with high viscosity are processed – accordingly, the requirements for valves, actuators and availability are very high.
At a glance
- Industry: Chemical industry / paint manufacturing
- Application: Production hall with dissolvers, mixers and tank system
- Medium / Process: Solvents, high-viscosity binders, water-based paints
- Challenge: High viscosities, high torques, ATEX requirements, short implementation phase
- STASTO solution: Complete valve package including coordinated actuator and automation technology
- Result: Technically coordinated overall solution with reduced procurement complexity and high operational reliability
The challenge
As part of the construction of a new production hall for paint manufacturing, the complete valve package for transfer lines as well as for mixing and tank processes was to be procured centrally. The media used include solvent-containing substances, sticky binders with high viscosity, and water-based paints.
Higher-range viscosities result in increased torques on shut-off and control valves. At the same time, there are requirements for ATEX-compliant versions, particularly in the area of limit switch boxes and actuators. In addition to technical suitability, rapid spare parts availability was required in order to minimize downtime in the future as well.
Standard solutions were not sufficient due to the combination of media characteristics, torque requirements, and explosion protection. In addition, the project’s short implementation phase posed an organizational challenge.
The STASTO solution
STASTO provided a complete valve package designed for the high viscosities and the resulting torques. Suitable industrial valves with matched pneumatic actuators as well as ATEX-compliant limit switch boxes were used.
Particular attention was paid to robust designs, chemical resistance to solvents, and reliable sealing when selecting the components. The actuator design was carried out taking into account the increased actuation forces in order to ensure reliable operation even with highly viscous media.
Thanks to close coordination with the plant manufacturer, all valves could be delivered ready for installation and integrated into the existing automation structure. The short project duration represented a logistical challenge, which was met in cooperation with the machine and plant manufacturer.
The result
The operator has a central point of contact for the entire valve product range. The procurement processes have been simplified and the interfaces reduced.
The components used ensure a reliable shut-off and control function even with highly viscous media. The ATEX-compliant design increases operational safety in potentially explosive atmospheres. Maintenance and spare parts processes are clearly structured, thereby minimizing downtime risks.
Added value for machine builders
- Technically coordinated complete package of valves and actuators
- Reduced interfaces in planning and procurement
- ATEX-compliant components from a single source
- Safe design for highly viscous media
- Plannable spare parts availability
This solution is particularly suitable for
- Production plants of the paint and coatings industry
- Chemical process plants with solvent-based media
- Mixing and dissolver systems
- Tank storage and conveying technology
- Applications with increased torque requirements
Contact
Are you planning a process or production plant with demanding media and specific requirements for your valve technology?
Talk to our experts – we will be happy to advise you.