Installation of Russell Finex’s high-performance self-cleaning filters double the production of water-based emulsion for Visen
Visen is widely known as one of the top producers of water-based emulsion. With its products being sold to numerous long-established paint manufacturers across the world, and with manufacturing facilities in several locations across India, Visen produces over 120,000 metric tonne of latex emulsion every year.
In 2011, to meet increased customer demand, Visen invested in new manufacturing facilities. Built in India, it was anticipated that the new plant would virtually double their production capacity to 220,000 metric tonnes per year. To ensure the new plant was equipped with the latest technologies, the company undertook a review of all their existing processes.
As a result of the review, it was identified that the existing quality control procedure in place for check-screening the latex emulsion prior to packing needed to be improved. The current procedure was carried out using a simple filter cloth system, which would catch any contamination in the paint as it is fed into the packing containers.
Although fit for purpose, improvements were identified, which if implemented would provide significant increases in production efficiency. Being an open system meant the cloths and paint were exposed to atmospheric influences which increased the possibility of skins forming in the latex emulsion. This could cause the industrial filtration equipment to block or end up contaminating the final product. As a result, machine operators were required to continually watch the line, which increased their exposure to the latex emulsion. In addition, the filter cloths needed to be changed between each new batch, and with several filling lines in operation, up to ten filter cloths could be used in any one day. As the cloths were not reusable, the company also incurred high disposal and replacement costs.
Whilst they recognised its importance they also acknowledged the inefficiencies of this existing system. In search for a new filtration system, Visen attended the Middle East Coatings Show in Dubai to talk to potential suppliers. Intrigued by the filtration system on display at the Russell Finex stand, Visen approached stand representatives to learn more about the machine. With an in-depth consultation provided, an onsite trial was arranged for the Self Cleaning Russell Eco Filter.
With the filter installed into their own production line, the trial enabled Visen to undertake personal monitoring of the machine’s effectiveness. “It was important for us to be able to trial the filter at our plant prior to purchase, not only to ensure that product quality would not be compromised, but also to ensure operators would be safeguarded from the potentially harmful fumes,” states VM Salunkhe, Manufacturing Manager, Visen’s plant in India. Following the success of the trials, Visen recognised the potential savings that would be gained prompting them to purchase ten Self-Cleaning Russell Eco Filters.
The installation of the industrial self-cleaning filtration system has enabled Visen to eliminate the problems associated with the previous system. With its reusable filter element, the Self-Cleaning Russell Eco Filters have minimised production downtime as stoppages to change filter cloths are no longer required. Substantial cost savings have also been gained as the removable element can be easily cleaned and used repeatedly, removing the high disposal and replacement costs, which Visen experienced with the filter cloth system.
A key requirement was for the new system to operate without constant supervision. Being a fully enclosed system, the product is unaffected by atmospheric elements and therefore minimises the possibility of skins forming in the latex emulsion, which would subsequently form blockages.
In addition, with the installation of the Russell Filter Management System which is designed to continuously monitor the filtration process, the filter is able to run efficiently without operator involvement. This not only safeguards operators from excessive exposure to the latex emulsion, but also releases the operators to perform other tasks around the factory.
Salunkhe states, “Compared to our previous manual filtration system, the enclosed Eco Filters have allowed us to achieve good housekeeping and reduce labour costs.”
The installation of the Russell Eco Filters has improved Visen’s manufacturing efficiencies whilst also enhancing their already meticulous quality control procedures.