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Water

Based Paint Filtration

water based paint filtration

Galaxy Sivtek designed and provided customized solution for a world-renowned paint and pigment manufacturing company

Client’s profile:

India’s biggest manufacturer of paint, pigment, wallpapers, waterproofing solutions, etc. The company is one of the oldest and biggest manufacturers of all kinds of paint, pigment, dry paint, various chemicals etc. for more than 7 decades they have been providing solutions for numerous paint and chemical requirements.

About the Product:

The client was looking for a robust classifying & screening machine that could help them sieve and screen Liquid Paint for contaminants, minute particles, and any other unwanted material which could hamper the quality of the product.

The customer wanted to sieve it is a water based acrylic emulsion suitable for dry to moderately humid climatic condition. It has special qualities such as weather resistance, longer shelf life, non-toxicity, APEO (Alkylphenol ethoxylates)-free, and environment friendly.

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Manufacturing of both paints has complex process & materials involvement. Pigments like Titanium Dioxide, chrome colors, zinc oxide along with solvents like Hydrocarbons, Alcohol is mixed with resins to make paint.

During the manufacturing & mixing process lumps are formed due to different chemical properties. Also, during the process material used to get contaminated so filtering the paint to remove lumps & make it contamination free was mandatory.

The company was using Nylon bag filters to separate oversize & foreign particles before final filling. Problems they faced with Nylon bag filters were

Frequently changing the bag: The Viscosity of paint is more, as a result, it doesn’t easily pass through the bag for the filtration process. The operator needs to squeeze the bag to make sure paint is being passed thru & during this process, the opening of the mesh gets bigger. Due to bigger mesh openings lumps pass thru in final product & so bags need to be changed frequently, which increased their production cost.

Inventory & Stock management: Due to more usage of Nylon bag filters, the company needed to maintain stock of the bags for inventory management. Stocking the bags resulted in investment & increased their operational cost.

Disposal of used bags: It was becoming a headache for the company to store & dispose of the used bags as environmental policies are quite strict. They had to also invest in properly disposing of the used bags, which in return increased their production cost.

Manpower: Due to the manual process of filtering more manpower was required to manage filtering as well as final packing process.

Breakthrough in the Manufacturing process: As Nylon bag filter needs to be changed frequently & it didn’t allow for the continuous manufacturing process, which again affected operational & production cost.

Solution and Result:

The design team from galaxy Sivtek came up with a customized filter arrangement which was employed before the self-cleaning filter to remove the lumps and agglomerates. This custom arrangement was used to screen the material 2 times before the final product.

The first screening arrangement was used to de-lump the raw material before entering the progressive cavity pump (Screw pump), the working of the pump is the pumping element comprises of a precision machined single external helix metallic rotor, and a double internal helix elastomer stator. Due to the special profile of the rotor and stator set, a sealing line is formed along the axis of the rotor which is maintained at both static and dynamic conditions.

Because of the use of this rotor the raw product should not contain any lumps or agglomerate which can cause damage to the body of the pump ie the stator or the rotor, to solve this issue a special perforated screen with 2mm opening was used to remove the hard bumps and prevent choking of the filter.

The second round of filtering was done with the help of the self-cleaning filter with 600-micron backet, here the pre filtered water-based paint was fine screened to remove the final contaminants. Which was fed by the progressive cavity pump at a constant pressure.

Result:

The customized solution provided not just helped them to achieve the desired output but also helped to solve the main issues of choking, reduced time and manpower.

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