Paint companies will change production methods

Due to harsh environmental policies, high operating costs and other factors, the paint industry will undergo tremendous changes in five to ten years or even three to five years. It will slowly transition to technology and capital-intensive, and production methods will be greatly improved. With the changes, the investment in environmental protection and automated production is bound to increase.

The main reason for the environmental and cost-to-production automation was December last year. The Ministry of Industry and Information Technology released the “Guidelines for Energy-saving and Emission Reduction in the Petrochemical and Chemical Industry” (Consultation Draft). The “Opinions” pointed out that the petrochemical and chemical industries are the basic industries of the national economy in China. Energy and resource consumption and pollutant emissions in major industries. The "Opinions" also proposed that the circular economy and cleaner production should be fully implemented. Strengthen the clean production audit of the petrochemical and chemical industries, and adopt advanced and applicable technologies, processes, and equipment to implement clean production technology reforms in light of key areas and weak links in energy conservation and emission reduction; by 2017, the emission intensity of key industries will decrease by 30% compared to 2012. %the above.

In order to increase production efficiency and respond to the call for national environmental protection policies, Hongchang Chemical also further improved the production methods. Guo Xiyou said that this year will further speed up the automation of the production system, eliminate backward equipment, introduce fully automated production lines, increase production capacity by 1/3 without increasing manpower, and use machinery and equipment instead of manual operations. Product development leads the market towards automation.

"If the automated process of the production system, will greatly reduce labor intensity, reduce labor costs; improve the company's productivity, production efficiency; improve product quality, reduce production energy consumption. Clean process, in line with the trend of energy conservation and emission reduction environmental protection. Of course Ultimately, it will bring absolute advantages in cost and price to the company, enhance the company's core competitiveness, and achieve both social and economic benefits.” Guo Xiyou told the reporter. According to Guo Xiyou, in 2014, Hongchang’s fully automated building coating production line will be fully operational within a short period of time.

At present, China's paint industry has a high energy resource consumption and a large amount of pollutants has not yet been fundamentally changed. The level of technical equipment in the industry is uneven, and there is a wide gap between the work of energy conservation, clean production and comprehensive utilization of enterprises. There is a big gap between the energy consumption of enterprises' products and the production and displacement of pollutants and the international advanced level. The statistics, monitoring and evaluation system for energy-saving and emission reduction in the whole industry has yet to be established and improved. There is still a certain gap between the level of energy conservation and environmental protection and the requirements for the construction of ecological civilization.

According to the “Opinions”, by the end of 2017, the energy consumption of the industrial added value of petrochemical and chemical industries was down by 18% compared with 2012, and the comprehensive energy consumption of key product units continued to decline. The industry’s chemical oxygen demand and oxidation* , Ammonia nitrogen and nitrogen oxide emissions are reduced by 8%, 8%, 10% and 10% respectively, the unit industrial added value water consumption is reduced by 30%, the wastewater is fully treated and the discharge is stable, and the water recycling rate is increased to 93%. Above, the comprehensive utilization rate of new petrochemical and chemical solid wastes has reached 75%, and the harmless disposal rate of hazardous wastes has reached 100%.

With regard to such stringent environmental protection policies, it is difficult for the paint industry to meet the current policy requirements. In particular, in recent years, paint companies are faced with enormous operating pressures caused by rising raw material prices and a substantial increase in labor costs. It is estimated that it will be more difficult to invest funds to improve the production environment. However, judging from the current intensified weather in China's haze, environmental protection policies have become more stringent, paint companies can only comply with policy requirements, there is no other way.

“Under the environmental situation, Dexian Chemicals initiated a fully automated program-controlled coating production project, with the help of in-depth integration of industrialization and informatization, to accelerate the structural adjustment and upgrading of enterprises. This is not only in line with the country’s goal of building 'beautiful China'. And environmental policies are also conducive to the long-term sustainable development of our company, said Wang Zhixian, general manager of Fuzhou Dexian Chemical Co., Ltd.

It is understood that in September 2013, the annual production capacity of Dexi Chemical Industrial's Shaowu Eco-Industrial Park reached 50,000 tons. The fully automated program-controlled coating production project was formally put into production. The production equipment of the project is an imported fully automatic computer-controlled production system.

At present, due to the low level of comprehensive informationization in China's paint industry, the overall production index control method is mainly manual, resulting in low labor productivity, high production costs, large resource consumption, serious environmental pollution, and weak overall competitiveness. "If we want to change this situation and solve the current contradictions and difficulties, our country's paint companies urgently need a larger system and unified technology to improve production efficiency, and accelerate the technological reform through the integration of the two." Wang Zhixian said.

At the same time as the Shaowu Eco-Industrial Park was put into operation, Dexian Chemical also announced that the automatic computer color matching system was officially launched. "The significance of the system's launch is mainly reflected in clean production, improve color efficiency, and strengthen production management." Wang Zhixian told the reporter.

“Environmentally friendly paint production technology has become the focus of promotion in the paint industry. As a responsible paint company, it should set an example in environmental protection, and achieve both environmental benefits and economic benefits. The application of coating automation toning system will effectively reduce The consumption rate of fresh water, the reduction of waste water discharge, and the increase of water reuse rate are the tools for realizing the 'clean production' of paints, said Wang Zhixian.

The pace of change in production methods may speed up the paint manufacturing industry in terms of automated production. The most worthy of recognition is the non-Fujian Haodi Coating Technology Co., Ltd. The initiatives of Haodi Coatings in industrialization and information integration also represent the future direction of China's paint industry production methods.

It is understood that in November 2012, Haodi Coating's 300,000-ton fully automatic paint and resin production line was completed and put into production. It is understood that the company has created a number of first coatings industry: the world’s first fully automated process control coating production line; the world’s first Fully automatic on-line detection of acid value, viscosity, and degree of alcoholysis; the world's first fully automated powder feeding; the world's first use of non-artificial additives and color paste......

“Using conventional equipment, a 300,000-ton production scale coating company requires about 3,000 employees in the production line. With fully automated equipment, 300 will be sufficient, and the quality will be more secure.” Chairman of Haodi Coating Technology Co., Ltd. Ye Yaoyao said that Haodi realized the integration of industrialization and information technology, and will become the largest coating company in Asia's single plant after its production.

According to authoritative sources, this fully automatic coating production line with multiple independent intellectual property rights has achieved a number of major breakthroughs: the entire process of computer control; the entire process of online monitoring and testing, breakthrough and solution of the paint industry in the chemical reaction process by manual detection The reaction status leads to the problem of parameter lagging and poor quality uniformity among batches; fully automated powder feeding eliminates a lot of manual labor, saves a lot of labor costs, and effectively avoids human error; Hybrid disperser replaces high-power high-speed disperser, saves electricity and reduces consumption; uses robot to add additives and color paste to improve the precision of adding trace materials, avoiding artificial errors leading to unstable quality; using chemical exhaust catalysts, synchronization will be The production waste gas will be treated as non-toxic and odorless, meet the emission standards, and promote the energy conservation, emission reduction and clean production of the paint industry and even the chemical industry.

Ye Yaoyao stated that the current production mode of China's paint manufacturing industry is relatively backward, and it still requires a large number of workers to produce, which leads to low production efficiency and remains a labor-intensive industry; in addition, backward production methods also lead to environmental pollution and product quality. Less advanced issues are not consistent with the future direction of manufacturing. In the future, China's paint manufacturing industry still has a huge space for improvement in production methods. The current coating companies actively promote production automation.

From the perspective of the coating company itself, through the upgrading of production equipment, through the automation of the production process upgrade, can effectively ensure the stability and excellent product quality, greatly reduce the cost of human resources, and greatly reduce the energy consumption and material consumption levels of the unit product Through the intensive and comprehensive information processing of the production process that is closely linked to the production automation control system, the digitalization of the production process resource information and the automatic filing of production resource data are realized, which greatly reduces the manual intervention in the production process, and strengthens the ability of comprehensive production management and management decision-making. Comprehensive resource information provision to promote the efficiency of production process management.

“The original extensive production methods are far from meeting the requirements of enterprises. The enterprises are imminent about the need to adopt advanced production technologies to improve the management level. Standard metering, efficient equipment, full-process automation control, and intelligent system information integration The handling and cleanliness of a civilized production environment has become a significant symbol of modern paint production,” said the source.

With the emergence and application of emerging information technologies, traditional production methods are inevitably undergoing changes. With the closer integration of information technology and coating manufacturing, the production methods of the paint industry will change significantly in the future. The transformation of China's paint manufacturing into “China-made” has become mainstream.