David Savastano, Editor02.01.21
There has been a lot of interest in sustainability. While most of the attention comes from areas such as packaging, sustainability also includes how a company manages its resources. This is where production equipment comes in.
If a manufacturer isn’t making its products in the most efficient way possible, it is wasting resources as well as time and money. At a time when companies are juggling costs while margins are tight, being as energy-efficient and cost-effective as possible is critical.
Chris Rodgers, corporate director of TPM for INX International Ink Co., said that ink manufacturing has changed over the years, including the implementation of Total Quality Management and Lean systems.
“INX International is committed to the implementation of TPM (Total Productive Management), an improvement methodology incorporating all employees which enables continuous improvement of the manufacturing process,” Rogers noted. “TPM allows INX to incorporate tools and methodologies from Six Sigma, TQM, Lean, SPC and more.
Our BMS (Business Management System) provides us with the ability to completely incorporate ISO 9001, 14001 and 45001 with our TPM methodology into a focused system for management and improvement.”
As a result, Rogers said that INX looks for new capabilities from equipment.
“Utilizing the Early Management Pillar of TPM, INX evaluates new and potential equipment not only for manufacturing capability and capacity but also for a vertical startup, startup OEE and reliability. This includes ease of maintenance and LCC (Life Cycle Cost).”
Sophisticated new equipment also provides INX with better insights into efficiency.
“The impact will come from how companies want to gather and use Big Data platforms to guide them into better efficiency and higher qualities of manufacturing their end products,” Rogers concluded.
Production Equipment and Sustainability
The cost of manufacturing becomes a factor for everyone. In speaking with key suppliers of manufacturing equipment, they are seeing a lot of interest in sustainable production. For example, Sara Fulford, VP sales and marketing for Hockmeyer Equipment, said that Hockmeyer is seeing increasing interest in investing among its customers in the ink industry.
Christine Banaszek, sales manager, Charles Ross & Son Company, reported that customers are looking to invest in new milling and mixing equipment.
“We are seeing increased activity in the 3D printing and additive manufacturing sectors,” Banaszek added. “Specialty inks and electronic inks remain strong.”
“Many customers are considering to improve and or optimize current production processes by either upgrading or retrofitting existing equipment or through purchasing new, advanced technologies,” said Patrick Maeder, senior sales director, Grinding and Dispersion for Buhler Group, who added that Buhler is seeing growth in the packaging ink industries.
Leading manufacturers noted that equipment choice can help ink companies meet sustainability goals.
Fulford said that through testing clients’ products and processes in Hockmeyer’s lab, the company ensures its understanding of the application and the client’s needs and goals.
“This allows us to incorporate custom design elements specific to the application and batch sizes,” Fulford added. “We make certain that the machine, vessels, blades and motor are properly sized, that it provides for safe and efficient discharge and cleaning, that operators can safely and effectively operate the equipment, and that they are thoroughly trained in all aspects of operation and maintenance.”
“New equipment technologies often require smaller footprint but produce greater yields, are more energy efficient (kWhr/t), require less operational supervision, use longer-lasting materials and come with a variety of services such as remote analytics for process monitoring, troubleshooting and optimization,” Maeder reported.
“Together with the customer through face-to-face or virtual consultation, in-lab or onsite trials as well as drawing from decades of expertise and excellence in technology and engineering, we develop and propose solutions that meet or exceed specific production requirements as well as achieve sustainability and budget goals,” Maeder said.
“Companies that proactively review their mixing operation and invest strategically are better able to meet sustainability goals including waste reduction, yield improvement and lower processing costs,” Banaszek said.
Banaszek observed that energy-efficient mixing is an integral part of sustainable production, and also supports the continuing development of new sustainable ink technologies.
“We help customers perfect their mixing strategies through trial testing and rental programs,” added Banaszek. “We build well-designed equipment with integrated controls that enable rapid product development and efficient scale-up. The right mixer and control combination is essential for safety and batch-to-batch repeatability but also important for sustainability because it promotes longer service life. Electronic soft start for the agitators, overload protection and other features help prevent premature wear and mechanical failure. Proper routine maintenance and calibration can also be programmed into the controls.”
Fulford observed that production equipment choice can help ink companies meet sustainability goals.
“Upon installing high-efficiency rapid-flow dispersing and milling equipment that dramatically shortens processing times, manufacturers can significantly lower their energy consumption,” Fulford said. “We provide a series of mills that because of their high efficiency and [vacuum] airless operation, can also help manufacturers reduce the use of additives otherwise required if the formula was processed in atmospheric conditions. Over time, other objectives can be met, such as lower operator fatigue, enhanced safety records (due to the many safety features of the equipment and its closed system) and less material waste.”
Fulford added that by employing automated vessel cleaning systems that are closed, vented and achieve results much faster than manual cleaning, manufacturers can greatly increase wash solvent utilization, lower employee exposure to solvent fumes and harmful detergents, limit the release of VOCs into the atmosphere, maintain cleaner air in the plant environment, lessen the handling and disposal of hazardous materials and increase productivity.
New Advances in Production Equipment
To help their ink customers meet their needs, leading production equipment manufacturers have brought some new designs to the market. Maeder noted that Buhler traditionally has developed roller mills in the graphic arts industry, although it most recently launched its Visconomic bead mill.
“The Trias three roller mill is a fully automated, PLC controlled mill which allows for the precise reproduction of operational mill parameters which can be batch formula specific stored,” Maeder said. “The mill, when equipped with Viva roll technology, can adapt to product viscosity ranges from low to high. The latest development for the use in this industry is the Visconomic bead mill, a fully automated mill which operates with greater efficiency on a smaller footprint.”
Banaszek said that the Ross PreMax is a batch-style ultra-high shear mixer that outperforms high-speed dispersers, traditional rotor/stator mixers and immersion mills. Its patented rotor is contoured for high pumping capacity and shear intensity, drawing product from above and below it, while expelling material radially through the stator slots at high velocity.
“The upper and lower vortices allow for extremely efficient powder additions and rapid turnover rates,” Banaszek added. “Depending on the ink application, the PreMax may eliminate the need for downstream milling. One-pot processing eliminates transfer steps and simplifies clean-up, dramatically cutting overall cycle time while reducing costs.”
Fulford said that the NexGen line of mills is Hockmeyer’s most recent addition to its ink production line.
“These rapid-flow recirculating vacuum mills are designed to radically enhance efficiency and help boost productivity,” Fulford noted. “They eliminate air entrapment in the feedstock, which allows for much faster flow rates that drastically reduce process times and increase yields.
“Key objectives in product development are to achieve fast and efficient results safely, maximize yields and minimize waste, all while enhancing the eco-efficiency of our equipment as well as of the processes they perform,” added Fulford.
If a manufacturer isn’t making its products in the most efficient way possible, it is wasting resources as well as time and money. At a time when companies are juggling costs while margins are tight, being as energy-efficient and cost-effective as possible is critical.
Chris Rodgers, corporate director of TPM for INX International Ink Co., said that ink manufacturing has changed over the years, including the implementation of Total Quality Management and Lean systems.
“INX International is committed to the implementation of TPM (Total Productive Management), an improvement methodology incorporating all employees which enables continuous improvement of the manufacturing process,” Rogers noted. “TPM allows INX to incorporate tools and methodologies from Six Sigma, TQM, Lean, SPC and more.
Our BMS (Business Management System) provides us with the ability to completely incorporate ISO 9001, 14001 and 45001 with our TPM methodology into a focused system for management and improvement.”
As a result, Rogers said that INX looks for new capabilities from equipment.
“Utilizing the Early Management Pillar of TPM, INX evaluates new and potential equipment not only for manufacturing capability and capacity but also for a vertical startup, startup OEE and reliability. This includes ease of maintenance and LCC (Life Cycle Cost).”
Sophisticated new equipment also provides INX with better insights into efficiency.
“The impact will come from how companies want to gather and use Big Data platforms to guide them into better efficiency and higher qualities of manufacturing their end products,” Rogers concluded.
Production Equipment and Sustainability
The cost of manufacturing becomes a factor for everyone. In speaking with key suppliers of manufacturing equipment, they are seeing a lot of interest in sustainable production. For example, Sara Fulford, VP sales and marketing for Hockmeyer Equipment, said that Hockmeyer is seeing increasing interest in investing among its customers in the ink industry.
Christine Banaszek, sales manager, Charles Ross & Son Company, reported that customers are looking to invest in new milling and mixing equipment.
“We are seeing increased activity in the 3D printing and additive manufacturing sectors,” Banaszek added. “Specialty inks and electronic inks remain strong.”
“Many customers are considering to improve and or optimize current production processes by either upgrading or retrofitting existing equipment or through purchasing new, advanced technologies,” said Patrick Maeder, senior sales director, Grinding and Dispersion for Buhler Group, who added that Buhler is seeing growth in the packaging ink industries.
Leading manufacturers noted that equipment choice can help ink companies meet sustainability goals.
Fulford said that through testing clients’ products and processes in Hockmeyer’s lab, the company ensures its understanding of the application and the client’s needs and goals.
“This allows us to incorporate custom design elements specific to the application and batch sizes,” Fulford added. “We make certain that the machine, vessels, blades and motor are properly sized, that it provides for safe and efficient discharge and cleaning, that operators can safely and effectively operate the equipment, and that they are thoroughly trained in all aspects of operation and maintenance.”
“New equipment technologies often require smaller footprint but produce greater yields, are more energy efficient (kWhr/t), require less operational supervision, use longer-lasting materials and come with a variety of services such as remote analytics for process monitoring, troubleshooting and optimization,” Maeder reported.
“Together with the customer through face-to-face or virtual consultation, in-lab or onsite trials as well as drawing from decades of expertise and excellence in technology and engineering, we develop and propose solutions that meet or exceed specific production requirements as well as achieve sustainability and budget goals,” Maeder said.
“Companies that proactively review their mixing operation and invest strategically are better able to meet sustainability goals including waste reduction, yield improvement and lower processing costs,” Banaszek said.
Banaszek observed that energy-efficient mixing is an integral part of sustainable production, and also supports the continuing development of new sustainable ink technologies.
“We help customers perfect their mixing strategies through trial testing and rental programs,” added Banaszek. “We build well-designed equipment with integrated controls that enable rapid product development and efficient scale-up. The right mixer and control combination is essential for safety and batch-to-batch repeatability but also important for sustainability because it promotes longer service life. Electronic soft start for the agitators, overload protection and other features help prevent premature wear and mechanical failure. Proper routine maintenance and calibration can also be programmed into the controls.”
Fulford observed that production equipment choice can help ink companies meet sustainability goals.
“Upon installing high-efficiency rapid-flow dispersing and milling equipment that dramatically shortens processing times, manufacturers can significantly lower their energy consumption,” Fulford said. “We provide a series of mills that because of their high efficiency and [vacuum] airless operation, can also help manufacturers reduce the use of additives otherwise required if the formula was processed in atmospheric conditions. Over time, other objectives can be met, such as lower operator fatigue, enhanced safety records (due to the many safety features of the equipment and its closed system) and less material waste.”
Fulford added that by employing automated vessel cleaning systems that are closed, vented and achieve results much faster than manual cleaning, manufacturers can greatly increase wash solvent utilization, lower employee exposure to solvent fumes and harmful detergents, limit the release of VOCs into the atmosphere, maintain cleaner air in the plant environment, lessen the handling and disposal of hazardous materials and increase productivity.
New Advances in Production Equipment
To help their ink customers meet their needs, leading production equipment manufacturers have brought some new designs to the market. Maeder noted that Buhler traditionally has developed roller mills in the graphic arts industry, although it most recently launched its Visconomic bead mill.
“The Trias three roller mill is a fully automated, PLC controlled mill which allows for the precise reproduction of operational mill parameters which can be batch formula specific stored,” Maeder said. “The mill, when equipped with Viva roll technology, can adapt to product viscosity ranges from low to high. The latest development for the use in this industry is the Visconomic bead mill, a fully automated mill which operates with greater efficiency on a smaller footprint.”
Banaszek said that the Ross PreMax is a batch-style ultra-high shear mixer that outperforms high-speed dispersers, traditional rotor/stator mixers and immersion mills. Its patented rotor is contoured for high pumping capacity and shear intensity, drawing product from above and below it, while expelling material radially through the stator slots at high velocity.
“The upper and lower vortices allow for extremely efficient powder additions and rapid turnover rates,” Banaszek added. “Depending on the ink application, the PreMax may eliminate the need for downstream milling. One-pot processing eliminates transfer steps and simplifies clean-up, dramatically cutting overall cycle time while reducing costs.”
Fulford said that the NexGen line of mills is Hockmeyer’s most recent addition to its ink production line.
“These rapid-flow recirculating vacuum mills are designed to radically enhance efficiency and help boost productivity,” Fulford noted. “They eliminate air entrapment in the feedstock, which allows for much faster flow rates that drastically reduce process times and increase yields.
“Key objectives in product development are to achieve fast and efficient results safely, maximize yields and minimize waste, all while enhancing the eco-efficiency of our equipment as well as of the processes they perform,” added Fulford.
