Intelligent Plants, Automated Efficiency
Seamless control, smart management, precise recipe mixing: With the introduction of digital products from QUAT²RO, KLB Kötztal Lacke + Beschichtungen GmbH benefits from the numerous advantages of pioneering automation and digitization solutions. With a 25-year company history, the family-owned business 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 realized not only through innovative concepts and extensive expertise but also through the modern, efficient production and manufacturing facility. In the expansion and modernization of production capabilities, as well as comprehensive digital process optimization, KLB Kötztal GmbH finds the ideal partner in the Westphalian company HAVER & BOECKER OHG, along with its subsidiaries, the technology companies Sommer Maschinen- und Anlagenbau and QUAT²RO. New Facility, New Opportunities: From Construction to Automation The expansion and automation of production at KLB Kötztal GmbH kicked off in August 2016 with the commissioning of the construction of a new coating facility at HAVER'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. "In the next step, the goal is to bring the new coating facility to life. And that's where we come in," reports Wilhelm Reinkemeier, Head of Engineering at QUAT²RO. In close coordination with the experts at the client and the sister company Sommer, needs are analyzed, specifications are defined, and solutions are developed. The automation of the coating facility aims to realize a multitude of optimizations by meeting two essential requirements: 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.
QUAT²RO® Batch: Precise Mixing, flexible Configuration
For approximately 20 years, the various batch management systems from QUAT²RO have represented 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 GmbH, the system solution is customized to individual specifications. "Here, the specific plant orientation, driven by the mixing of liquids and solids, is particularly noteworthy," explains Wilhelm Reinkemeier. 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 Southern German production company is adhering to guidelines regarding explosion protection when adding flammable substances. QUAT²RO® Batch provides the right and forward-looking 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," emphasizes QUAT²RO engineer Wilhelm Reinkemeier. Maximum reliability and satisfied customers are the results, along with effective support for in-house quality management: "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 digitalization 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 optimized. The results are both tangible and measurable: machines and systems are more efficiently utilized, resources such as raw materials, energy, and time are saved, and errors are minimized.
QUAT²RO® Process Visualization: Effortless Control, Seamless Monitoring
With the installation of the innovative process control system from QUAT²RO, the new coating facility of the renowned manufacturer is complemented by the proverbial "eyes and ears" that miss no relevant information. Based on proven visualization standards, QUAT²RO® Process Visualization enables the central monitoring and operation of all integrated plant components. "The graphical representation of the plant's condition ensures the best possible overview," summarizes Wilhelm Reinkemeier. 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.
More QUAT²RO for Every Need
"Every pump, every screw-conveyor, every element of the production process can be individually and precisely controlled – all fully automated. All connected components communicate with each other, enabling a more efficient, cost-effective, and reliable production. Furthermore, contemporary process visualization ensures not only the seamless observation, control, and monitoring of the production process but also its further optimization based on the collected data," summarizes QUAT²RO engineer Wilhelm Reinkemeier. At KLB Kötztal Lacke + Beschichtungen GmbH, the mixing process management QUAT²RO® Batch, together with the process control system QUAT²RO® Process Visualization and the mixing systems from Sommer, positively revolutionize the production processes. With digital system solutions of the QUAT²RO® family, the Westphalian company QUAT²RO GmbH & Co. KG offers customers and interested parties comprehensive support along the entire value chain of bulk and liquid goods.
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