All systems go: Europe's most modern water-based paint factory goes into operation in Schwaz

FLEXIBLE PRODUCTION IN TOP QUALITY

More than 70 stainless steel tanks have been set up in the newly erected hall, 4,000 valves installed, and over 80 km of cables and pipes laid. "With this production facility we are setting new standards for modern, modular paint manufacture," says Andreas Knapp, who coordinated the construction of the new factory as the project manager: a high-tech process control system, the latest plant engineering and a whole new production process with semi-finished products will provide the highest level of flexibility, efficiency and quality.

A key element is an ultra-modern system of pig lines: 13 lines running a total length of 2 km have been installed in the factory building. The "pig" ensures that exactly the right amount of water, binding agent or finished paint is transferred from one tank to another and that the line is cleaned at the same time. This guarantees fast and flexible processes and minimises material losses. As the last piece in the puzzle, a fully automated filling line has been installed, on which an ultra-modern robot palletises containers from 3-litre up to 27-litre buckets. The facility simultaneously prepares the matching labels and sticks them on the container.

ENVIRONMENTALLY-FRIENDLY CONSTRUCTION

The factory building itself is also state of the art. A groundwater heat pump and a photovoltaic system on the roof provide an environmentally-friendly supply of energy. The timber construction of the building is also ecological: the 15-metre high hall with a floor space of over 3,000 m2 is supported by just three concrete pillars. Not only the roof but also the outer walls are made of wood – coated with the elegant greying glaze, Pullex Silverwood from ADLER, the expert in wood preservation.

PAINT INDUSTRY 4.0

Over the past few weeks, all production procedures have been simulated in test mode with water and the digital interfaces have been adjusted. The facility is controlled by touch screen using a modern process control system – in future the skilled workers' dexterity instead of their physical strength will be called on. "We have thus set the course towards paint industry 4.0," says Christian Steurer, Head of Logistics at ADLER. What happens now? "We have successfully completed the 'water games', in other words the comprehensive test phase. Still to come in June, the tanks will be filled with binding agent and the first paints produced – to start with, various products from the window coating range," says Andreas Knapp.

INVESTMENT OF 30 MILLION EURO

With the construction of the new water-based paint production – an investment of approx. 30 million euro – ADLER concludes the first building stage of the "ADLER 2020" project. In the second stage, a new high-bay warehouse and logistics centre are currently being built in Schwaz. Up to 30,000 tonnes a year of water-based paint will be able to be produced at the new factory in future.
ADLER Managing Director, Andrea Berghofer: "We have successfully counted on water-based paints at ADLER for almost 40 years – because water-based paints are good for wood and good for the environment. "With the new production facility, we are able to meet the ever-increasing demand and are equipped for a successful future."