2. Turnkey Solution from Concept to Commissioning
Wahal’s ability to provide a turnkey solution means they can manage the entire project, allowing the client to focus on their core business. This includes:
- Process Design and Layout: Wahal’s team would design a complete plant layout, from the storage of raw materials to the final filling and packaging. They would create an optimized process flow that is efficient, scalable, and adheres to safety and quality standards.
- Equipment Manufacturing and Integration: Wahal would manufacture the core equipment, including high shear mixers, dispersers, reactors, and storage tanks. More importantly, they would integrate these components with other necessary machinery, such as pumps, filtration systems, and filling lines, to create a cohesive and automated plant.
- Automation and Quality Control: VOC-free coatings require tight control over process parameters like temperature, mixing speed, and pressure. Wahal’s expertise includes integrating PLC/HMI-based control systems to automate the entire process, ensuring batch-to-batch consistency and high-quality output. This is crucial for a product whose performance depends on precise formulation.
3. Addressing Specific Challenges of VOC-Free Coatings
Wahal’s expertise is particularly valuable because it directly addresses the unique challenges of manufacturing VOC–free barrier coatings:
- Aeration Control: Water-based formulations are prone to air entrainment during mixing, which can lead to defects in the final coating. Wahal’s inline mixers and vacuum-rated vessels can be used to perform mixing in a closed system, preventing air from being introduced and ensuring a smooth, bubble-free product.
- Temperature Sensitivity: Many water-based polymers and additives can be sensitive to heat. Wahal’s mixers are designed to be highly efficient, reducing the overall mixing time and the heat generated. They can also integrate cooling jackets on vessels to maintain a stable temperature throughout the process.
- Rheology and Viscosity Control: The rheology (flow properties) of a coating is critical for its application. Wahal’s equipment can handle a wide range of viscosities and is used to create a final product with the desired flow properties, ensuring it can be applied smoothly by various methods (e.g., spraying, roller coating) without defects.
By leveraging their deep knowledge of high shear mixing and their ability to deliver comprehensive turnkey solutions, Wahal can provide clients with a complete and optimized plant for the production of VOC–free barrier coatings, enabling them to enter this high-growth market with a high-quality and sustainable product.
