Turnkey project supplier for industrial waterborne coatings

2. Comprehensive Turnkey Solution

As a turnkey supplier, Wahal removes the complexity and risk from the client’s side, managing every stage of the project. Their advantage lies in their ability to provide:

• Integrated Design and Engineering: Wahal doesn’t just sell individual pieces of equipment; they design a complete, customized plant. This includes process flow design, equipment sizing, vessel layouts, and piping diagrams. They ensure that every component, from the raw material storage tanks to the final filling station, is integrated for maximum efficiency.
• In-house Equipment Manufacturing: Since Wahal manufactures their own high-quality mixers, dispersers, and mills, they have complete control over the quality, performance, and customization of the core processing equipment. This also simplifies maintenance and spare parts availability for the client.
• Automation and PLC/HMI Integration: A modern waterborne coatings plant must be highly automated to ensure batch-to-batch consistency and a safe operating environment. Wahal’s expertise includes designing and integrating a PLC (Programmable Logic Controller) system with an HMI (Human-Machine Interface) to control the entire plant, from ingredient dosing to process parameters like temperature and mixing speed.
• Quality Control and Safety: Wahal’s plant designs incorporate crucial quality control checkpoints, such as in-line viscometers and particle size analyzers. They also prioritize safety with features like dust-free powder handling systems and fail-safe controls, which are particularly important when dealing with fine powders and chemicals.

3. Addressing the Specific Challenges of Waterborne Coatings

Wahal’s deep understanding of waterborne formulations allows them to solve common manufacturing problems:

• Aeration Control: Water-based systems are susceptible to air entrainment, which can lead to foaming and defects in the final coating. Wahal’s inline mixers and vacuum-rated blending vessels can be designed to prevent air from being introduced, ensuring a dense, bubble-free product.
• Temperature Management: Many water-based binders are sensitive to heat. The intense shear from Wahal’s mixers generates heat, but their systems are designed to be highly efficient, reducing processing time and incorporating cooling systems to maintain the optimal temperature throughout the process.
• Reduced Processing Time: The powerful shearing action of Wahal’s equipment significantly cuts down the mixing and grinding time compared to conventional methods. This leads to higher production output, lower energy costs per batch, and a faster return on investment for the client.

   

By leveraging their technical expertise and offering a comprehensive, integrated solution, Wahal positions itself as a key partner for companies looking to enter or expand in the industrial waterborne coatings market. They provide the technology and support necessary to produce high-quality, sustainable coatings efficiently and cost-effectively.