Painting & Coating Industry (PCI) logo Powder coating summit logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • MATERIALS
  • TECHNOLOGIES
  • RESOURCES
  • EVENTS
  • DIRECTORIES
  • EMAGAZINE
  • CONTACT
  • SIGN UP!
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest News
  • Market Trends & Reports
  • Price Alerts
  • Subscribe to eNewsletters
  • Global Top 10/ PCI 25
  • Weekly Featured Article
  • COATLE Word Game
  • PRODUCTS
  • Product News
  • Must See Products and Services
  • MATERIALS
  • Additives
  • Resins/Polymers
  • Pigments
  • Equipment
  • Distributors
  • TECHNOLOGIES
  • Adhesives
  • Architectural Coatings
  • FINISHING
  • Industrial Coatings
  • Nanotechnology
  • Powder Coatings
  • Solventborne
  • Special Purpose Coatings
  • Sustainability
  • UV Coatings
  • Waterborne
  • FINISHING
  • Finishing News
  • Finishing Technologies
  • Finishing Equipment
  • Finishing Today
  • RESOURCES
  • Columns
  • Blogs
  • Coatings Supplier Handbook
  • Podcasts and Videos
  • PCI Store
  • Classifieds
  • eBooks
  • Sponsor Insights
  • White Papers
  • COATLE Word Game
  • Columns
  • Ask Joe Powder
  • Did you know?
  • Distribution Dive
  • Focus on Canada
  • Formulating With Mike
  • Innovation Insights
  • Moody's Coatings Conundrums
  • Powder Coating Perspectives
  • Target the Market
  • TiO2 Insider
  • Blogs
  • Editor's Viewpoint
  • Industry Insights
  • Podcasts and Videos
  • COAT-IT! Podcast
  • Videos/PCI TV
  • EVENTS
  • Coatings Trends & Technologies Summit
  • Paint and Coatings Academy
  • Webinars
  • Calendar of Events
  • Lifetime Achievement Award
  • DIRECTORIES
  • Buyer's Guide
  • Equipment Directory
  • Materials Directory
  • EMAGAZINE
  • Current Issue
  • eMagazine Archive
  • China Issue Archive
  • Editorial Advisory Board
  • CONTACT
  • Contact Us
  • Advertise
  • Subscribe to eMagazine
  • Subscribe to eNewsletters
Painting & Coating Industry (PCI) logo Powder coating summit logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Painting & Coating Industry (PCI) logo Powder coating summit logo
  • NEWS
    • Latest News
    • Market Trends & Reports
    • Price Alerts
    • Subscribe to eNewsletters
    • Global Top 10/ PCI 25
    • Weekly Featured Article
    • COATLE Word Game
  • PRODUCTS
    • Product News
    • Must See Products and Services
  • MATERIALS
    • Additives
    • Resins/Polymers
    • Pigments
    • Equipment
    • Distributors
  • TECHNOLOGIES
    • Adhesives
    • Architectural Coatings
    • FINISHING
      • Finishing News
      • Finishing Technologies
      • Finishing Equipment
      • Finishing Today
    • Industrial Coatings
    • Nanotechnology
    • Powder Coatings
    • Solventborne
    • Special Purpose Coatings
    • Sustainability
    • UV Coatings
    • Waterborne
  • RESOURCES
    • Columns
      • Ask Joe Powder
      • Did you know?
      • Distribution Dive
      • Focus on Canada
      • Formulating With Mike
      • Innovation Insights
      • Moody's Coatings Conundrums
      • Powder Coating Perspectives
      • Target the Market
      • TiO2 Insider
    • Blogs
      • Editor's Viewpoint
      • Industry Insights
    • Coatings Supplier Handbook
    • Podcasts and Videos
      • COAT-IT! Podcast
      • Videos/PCI TV
    • PCI Store
    • Classifieds
    • eBooks
    • Sponsor Insights
    • White Papers
    • COATLE Word Game
  • EVENTS
    • Coatings Trends & Technologies Summit
    • Paint and Coatings Academy
    • Webinars
    • Calendar of Events
    • Lifetime Achievement Award
  • DIRECTORIES
    • Buyer's Guide
    • Equipment Directory
    • Materials Directory
  • EMAGAZINE
    • Current Issue
    • eMagazine Archive
    • China Issue Archive
    • Editorial Advisory Board
  • CONTACT
    • Contact Us
    • Advertise
    • Subscribe to eMagazine
    • Subscribe to eNewsletters
  • SIGN UP!

Ink Production Plant Rebuilt to Improve Product Quality and Meet Environmental Regulations

March 1, 2009


Gravure printing has continually lost share in the printing market since the 1950s. Alternate technologies and, more recently, environmental demands have pressured ink makers to find new applications, new technologies and better processes. And in the last 10 years the industry has responded. But even these positive changes have put pressure on producers. Sun Chemical, the world’s largest producer of printing inks and pigments, was aware that it needed to continue to evolve with the changing industry to remain its leader.

In 2004, the company began the phased relocation of its publication gravure ink production from Watford, England, just outside of London, to the existing Sun Chemical Ltd., site in Rochdale, Lancashire, about 200 miles to the north. The company’s goal was a standalone publication gravure ink plant that would utilize all new equipment and production processes to generate 30,000 metric tons of ink per year. The plant’s design incorporated the latest process control technology, designated manufacturing and raw materials storage. It would operate five lines, one for each color, and a fifth line for varnishes and extenders. It also included a tank farm for storing liquid raw materials, intermediate products and finished inks.

Sun looked to outsource the role of principal contractor. The vendor would be responsible for plant design and construction, and would need to follow Construction, Design and Management (CDM) regulations while overseeing safe site operations during construction and testing phases.

Sun Chemical invited Netzsch-Mastermix Ltd. (UK) to participate in a trial. A team of Netzsch engineers and Sun Chemical technical staff tested prospective plant throughputs and efficiencies. Netzsch engineers then proposed a plan for a facility that met Sun Chemical’s guidelines for product quality, volume and yearly output. The plant would be capable of pigment milling 116 to 204 kilograms per hour, and the combined mill base outputs could reach 2300 kilograms per hour.

The Netzsch team would design and engineer the plant, specify equipment and manage the construction and plant start-up on a turnkey basis. It would also manage main site services and the installation and commissioning of all ancillary equipment. Acutely aware that time is money, Sun set a narrow 48-week timetable to go from completed plans all the way to live chemical trials.

Plant Design Challenges

Manufacturing high-quality publication gravure ink presents many challenges. For starters, materials used in the process have high solids concentrations at the grinding stage, making them viscous and difficult to pump. The toluene solvents used to produce the inks can be potentially hazardous to the environment, requiring a completely closed ink-production system. These were only two of the most obvious obstacles.

So the two teams worked together to select suppliers based on their technical understanding of the products, the availability of service and backup support, ability to meet schedules and cost effectiveness. On-time delivery would play a key role in the overall timescale of the project. The team educated suppliers and provided them with installation and commissioning plans to emphasize the importance of scheduling.

The team selected a combination of machines – PMD (pre-mixer disperser) batch disperser technology, upgraded LME horizontal bead mills and a PSI-Mix inline disperser. Plant utilization was split between simple intermediate product production on PMD machines and ink production on the LME and PSI combination.

The LME horizontal bead mill allowed Sun to increase throughput rates with virtually no blockage. Its triple lobe disc actively counteracts product flow using a “triple screw” effect. Because temperatures can rise significantly when grinding very viscous materials, like those used in the publication gravure process, the large cooling surfaces of the LME mill protect the integrity of the product. By keeping temperatures down, the materials’ properties are not altered. A dynamic cartridge media separator pre-classifies beads 0.1 mm to 5 mm and centrifuges them away from the screen. This prevents compaction of the beads, resulting in high power draw and therefore high product temperature, which can degrade the resin in the ink and change the pigment shade.

The PSI mixer, an inline disperser, achieves homogeneous, fine dispersions using a controlled process. Netzsch was challenged to optimize the speed (rpm) of each PSI unit on each line to deal with the characteristic differences for each pigment. Black pigment, for instance, is hard to break down but easy to handle, while red is easier to process but difficult to handle. The combination of vacuum dispersing, shearing and pressure wetting proved successful, giving Sun excellent results and reproducible quality.

Additionally, a vacuum feeding system eliminated emissions-related hazards. The system has very low dust emission, reduces solvent emissions and the waste of solvents. It is environmentally friendly because it degasses during mixing in a totally closed system. Doing so helps the plant meet the United Kingdom’s ATEX directives for workplace health and safety. But the vacuum system also provides a production advantage: it disperses agglomerates so that each particle is encapsulated. This improves efficiency and total throughput.

Concept to Power-Up in 48 Weeks

With less than a year to have the plant up and running, Netzsch arrived at the site in October 2005 to supervise installation of the plant under CDM regulations. “We were on site for every hour of the construction to ensure that work was completed safely and on time,” said Scott Stephenson, Netzsch project manager. “We were responsible for the safety of up to 50 contractors working alongside each other.”

The delivery and erection of the first mezzanine support steelwork occurred in stages that coincided with the arrival of 32 machines from the Netzsch production facility in Germany. Within eight weeks, steel was built around all of the Netzsch machinery.

At the same time, pipe work and the tank farm phases of the construction were underway. The installation of 21 bulk storage tanks with capacities ranging from 65,000 liters to 120,000 liters in two bounded areas – one for raw, the other for finished goods – went successfully.

By late December, the team completed positioning all major plant items and all materials necessary to complete the installation of the process plant, and ancillary services were on site. Within one month, workers installed internal pipe-work manifolds in sections, with the process valves, and erected interconnecting tank farm pipe work and supports.

In mid-March, operational staff arrived to assist in sequence checks and become familiar with the HMIs, control systems and general plant operation. The Sun Chemical/Netzsch team began power-up of the plant, running successful input/output (I/O), rotation and instrumentation checks.

After calibration and dry sequence checking, the team began using water to run wet testing on the miles of pipe work, valves, pumps and vessels. The team members’ extensive experience in hazardous atmospheres ensured safe operation at this testing phase. After every possible sequence was run and checked by both sides of operations staff, the pipe work and tanks were drained and prepped for product trials.

The team began product trials and plant start-up with solvents in early April 2006, and ramped up production on all four color lines, the resin plant and the additives plant to ensure production targets and guarantees. This continuous process led to full production and, eventually, product supply to final customers at the end of May 2006.

In the end, the results were significant and a vast improvement over Sun’s old Watford plant. The Rochdale plant produces blue and black pigments in 12-metric ton batches. Batch times are approximately 12 hours compared to 48 hours at the old facility. Seven-metric ton red and yellow pigment batches are completed in less than 5 hours compared to 7 hours in the Watford plant. And batch accuracy at Rochdale is now an impressive 0.001 percent.

“This investment is fundamental in ensuring Sun Chemical is aligned with the future growth of the Publication Gravure business,” said Sun Chemical’s managing director in charge of the UK in a press release issued by the company. “The new operation at Rochdale will re-enforce our commitment and leadership in this sector and cater to the growing re-emergence of Publication Gravure as a high-quality commercial printing process for the future.”

The UK-based NETZSCH Project Engineering team, assisted by German colleagues in machinery design and laboratory testing, brought together a turnkey plant of 32 machines and ancillaries on time and on budget. “Obviously we consider this project a success,” said David Tomlinson, managing director of NETZSCH-Mastermix Ltd. “One of the world’s largest ink producers entrusted us to design, engineer and construct a new plant with the latest technology, and it is running successfully today.” And now, almost two years since the plant opened, the Sun’s Rochdale location is guaranteed to produce more than 13,200 metric tons of ink per year, and is capable of producing 30,000 metric tons if operated at full capacity.

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • pci1022-Kinaltek-Lead-1170.jpg

    A Novel Pigment Production Technology

    Following an extensive R&D program that demonstrated...
    Paint and Coating Pigments
    By: Jawad Haidar and Nitin Soni
  • pci global top 10

    2025 Global Top 10: Top Paint and Coatings Companies

    The following is PCI’s annual ranking of the top 10...
    Paint and Coating Market Reports
    By: Courtney Bassett
  • 2025 pci 25

    2025 PCI 25: Top Paint and Coatings Companies

    PCI's annual ranking of the top 25 North American paint...
    Global Top 10 and PCI 25
    By: Courtney Bassett
You must login or register in order to post a comment.

Report Abusive Comment

Manage My Account
  • eMagazine
  • eNewsletter
  • Online Registration
  • Subscription Customer Service

The Coatings Minute: Your Inside Look at PCInnovations

The Coatings Minute: Your Inside Look at PCInnovations

CTT Registration Now Open

CTT Registration Now Open

The Coatings Minute: Your Guide to the 2025 Coatings Supplier Handbook

The Coatings Minute: Your Guide to the 2025 Coatings Supplier Handbook

The Coatings Minute: Print Returns with PCI’s New Showcase Issue

The Coatings Minute: Print Returns with PCI’s New Showcase Issue

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the PCI audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of PCI or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • Modern arapartment complex painted in bright colors.
    Sponsored byEPS - Engineered Polymer Solutions

    Architectural Polymers Leading the Way in Coatings Innovation

  • paint sprayer in a workshop
    Sponsored byallnex

    Enabling Performance and Compliance: allnex Introduces a New Line of VOC Exempt Solvent-Borne Resins

Popular Stories

No. 3 AkzoNobel

AkzoNobel’s $1.4B Divestment Signals Strategy Shift

PCI voices from the top

eBook | PCI Voices from the Top

Mergers and Acquisitions

RPM Expands Portfolio With Strategic Acquisition



PCI Buyers Guide

Submit a Request for Proposal (RFP) to suppliers of your choice with details on what you need with a click of a button

Start your RFP

Browse our Buyers Guide for manufacturers and distributors of all types of coatings products and much more!

Find Suppliers

Events

September 3, 2025

Coatings Trends & Technologies Summit

The Coatings Trends & Technologies (CTT) Summit is an annual conference for both liquid and powder coatings formulators and manufacturers to discuss innovations in coatings technology. This event combines high-quality technical presentations, a resource-rich exhibit hall, and dedicated networking opportunities to connect scientific minds, foster innovation, and cultivate game-changing new ideas!

January 1, 2030

Webinar Sponsorship Information

For webinar sponsorship information, visit www.bnpevents.com/webinars or email webinars@bnpmedia.com.

View All Submit An Event

Poll

Longest-running laboratory experiment

What is the longest-running laboratory experiment?
View Results Poll Archive

Products

CTT Summit Short Courses (Live 9/3/25)

Coatings Trends & Technologies Summit is expanding its offerings with four short courses. These short courses will offer an extensive day of interactive learning.

See More Products
pci voices from the top ebook

PCI CASE EBOOK

Related Articles

  • pci0811-Emerald-lg.jpg

    Foam-Control Solutions That Meet Today's Tighter Environmental Regulations

    See More
  • Heraeus Noblelight

    Infrared Emitters and UV Lamps Speed up Production and Improve Quality

    See More
  • Toyota Chooses Perceptron System to Improve Paint Quality & Consistency in Plants

    See More

Related Directories

  • Catalytic Products International

    Solving complex air pollution control challenges by combining world-class engineering with extensive application experience to deliver regenerative thermal oxidizers (RTOs), thermal oxidizers, catalytic oxidizers, and precious metal catalyst products. Other services include consulting, turnkey installations, permitting assistance, and maintenance service contracts. Catalytic Products International...Enabling Clean Production since 1969.
  • HERO Products Group

    A leader in dispensing and mixing equipment, supplying to the most prominent paint and coatings manufacturers and retailers. HERO provides world class manual and automatic dispensing equipment, mixers and shakers for retail point of sale, lab and in-plant factory production requirements. HERO can provide the right products for any need.
×

Keep the info flowing with our eNewsletters!

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletters
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey & Sample
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • Youtube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing

Painting & Coating Industry (PCI) logo Powder coating summit logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Painting & Coating Industry (PCI) logo Powder coating summit logo
  • NEWS
    • Latest News
    • Market Trends & Reports
    • Price Alerts
    • Subscribe to eNewsletters
    • Global Top 10/ PCI 25
    • Weekly Featured Article
    • COATLE Word Game
  • PRODUCTS
    • Product News
    • Must See Products and Services
  • MATERIALS
    • Additives
    • Resins/Polymers
    • Pigments
    • Equipment
    • Distributors
  • TECHNOLOGIES
    • Adhesives
    • Architectural Coatings
    • FINISHING
      • Finishing News
      • Finishing Technologies
      • Finishing Equipment
      • Finishing Today
    • Industrial Coatings
    • Nanotechnology
    • Powder Coatings
    • Solventborne
    • Special Purpose Coatings
    • Sustainability
    • UV Coatings
    • Waterborne
  • RESOURCES
    • Columns
      • Ask Joe Powder
      • Did you know?
      • Distribution Dive
      • Focus on Canada
      • Formulating With Mike
      • Innovation Insights
      • Moody's Coatings Conundrums
      • Powder Coating Perspectives
      • Target the Market
      • TiO2 Insider
    • Blogs
      • Editor's Viewpoint
      • Industry Insights
    • Coatings Supplier Handbook
    • Podcasts and Videos
      • COAT-IT! Podcast
      • Videos/PCI TV
    • PCI Store
    • Classifieds
    • eBooks
    • Sponsor Insights
    • White Papers
    • COATLE Word Game
  • EVENTS
    • Coatings Trends & Technologies Summit
    • Paint and Coatings Academy
    • Webinars
    • Calendar of Events
    • Lifetime Achievement Award
  • DIRECTORIES
    • Buyer's Guide
    • Equipment Directory
    • Materials Directory
  • EMAGAZINE
    • Current Issue
    • eMagazine Archive
    • China Issue Archive
    • Editorial Advisory Board
  • CONTACT
    • Contact Us
    • Advertise
    • Subscribe to eMagazine
    • Subscribe to eNewsletters
  • SIGN UP!