Seamless control, smart management, precise recipe mixing: With the introduction of digital products from Quat²ro, KLB Kötztal Lacke + Beschichtungen benefits from the numerous advantages of automation and digitalisation solutions.
With a 25-year mcompany history, the family-owned KLB Kötztal Lacke + Beschichtungen GmbH based in Bavarian Ichenhausen is now one of the leading providers of coating materials and reaction resins for industrial flooring. Perfectly coordinated, high-quality system solutions are the hallmark of this successful medium-sized company. The high standards of quality and service are realised not only through innovative concepts and extensive expertise but also through the modern, efficient production and manufacturing facility.
In the expansion and modernisation of production capabilities, as well as comprehensive digital process optimisation, KLB Kötztal finds the ideal partner in the Westphalian company Haver & Boecker, along with its subsidiaries, the technology companies Sommer Maschinen- und Anlagenbau and Quat²ro.
From construction to automation
The expansion and automation of production at KLB Kötztal kicked off in August 2016 with the commissioning of the construction of a new coating facility at Havers‘s subsidiary Sommer. The new mixing plant is precisely tailored to the client‘s requirements: mixers, silos, tanks, and containers, along with numerous scales, conveyor screws, pumps, pipelines, and various other components, ensure a seamless production of high-quality paints and coatings.
To bring the new coating facility to life is part of Quat²ro. The focus is not only on precise and reproducible mixing process management but also on the central monitoring and easy operation of all connected plant components.
Flexible batch management system
The batch management systems from Quat²ro allow intelligent configuration and management of complex mixing processes for bulk solids and liquids. For the blending of paints, adhesives, resins, and other products at KLB Kötztal, the system solution is customised to individual specifications. From silos and tanks to solid containers and barrels for smaller quantities, all components must be precisely weighed and transported to the mixer in the correct amount and order. Additional expertise is required at this stage, as the quality of the finished product depends significantly on the optimal duration and speed of mixing in the high performance dissolver from Sommer. An additional challenge for the company is adhering to guidelines regarding explosion protection when adding flammable substances. Quat²ro Batch provides the right solution for all these requirements.
From transparent production to reproducible quality, the mixing process management delivers valuable services. The special advantage lies in the consistent quality of the products with automatic compliance with weights and seamless tolerance monitoring. Thanks to Quat²ro Batch, all processes and raw materials are traceable without any gaps.
Furthermore, the batch management system impresses with a high degree of flexibility. In addition to the capability to manage an unlimited number of recipes and configure control recipes individually, it also seamlessly handles the creation and scheduling of orders, the generation of batch logs, reports, and statistics, as well as the automated management and documentation of production data, material consumption, inventory, and finished products – all surprisingly simple.
The portfolio of the digitalisation solution is completed by its communication with the company‘s ERP system: Thanks to the integration of the business and production levels, all processes from order management through the mixing process to logistics are optimised.
Seamless Monitoring
With the installation of the process control system from Quat²ro, the coating facility of the renowned manufacturer is complemented by the proverbial „eyes and ears“ that miss no relevant information. Based on proven visualisation standards, Quat²ro Process Visualisation enables the central monitoring and operation of all integrated plant components.
The graphical representation of the plant‘s condition ensures the best possible overview. Timely capture of operational and fault messages, along with comprehensive measurement data, provides valuable assistance from quickly detecting errors and identifying inefficient processes to informing about upcoming tasks.
Achema 2024: Hall 5.0, Booth B86
