DE102015118926A1 - Semi-finished products to building colors and building colors - Google Patents

Abstract

Standardized liquid semifinished product for the manufacture of architectural paints, whereby the semifinished product can be used both as a salable end product or as a basis for further processing and / or refinement.

Description

State of the art

The supply of commercial resellers, including hardware stores, in the full range and in particular range of building colors requires a high variety of variants, which is characterized by very short order and delivery intervals.

architectural coatings

Architectural paints and varnishes prevent the rapid deterioration of the building materials used in a building and keep the structures of the building functioning. The particular color scheme can change the appearance of the building.

A building includes a variety of different building materials, such. As wood, sandstone, brick, plaster, steel, concrete, reinforced concrete or glass. To fulfill its special protective function and other optical functions, the building color has an adhesive property adapted to the building material.

Preferably, the building paints are applied liquid. Drying and / or a chemical reaction transforms the initially liquid layer into a solid or firmly adhering color layer which fulfills its respective protective or optical function.

The building colors can be applied to the exterior facade of a building. Other building colors serve to protect and visually design the interior walls.

Other applications of architectural paints relate to corrosion, concrete and wood protection.

The production and the provision of depending on the manufacturer over many hundreds of different formulations requires a high degree of flexibility in the production sequence. Depending on the customer, the batches vary in size and in the time limit.

ingredients

The building paints preferably but not exclusively pigments, fillers, binders, additives and in some areas also solvents.

Conventionally, a variety of components are used for the production of each individual building color, which are processed according to a kind of standard formulation in sequence with the following ingredients in succession:
Water, dispersants, defoamers, cellulose, sodium hydroxide, solvents, resins, titania, powders, thickeners.

These individual components are added and further processed in subsequent process steps. Since this is done for each individual color to be produced, this means a very complex, cost-intensive, logistically demanding, expansive manufacturing process, the other devices and process sequences are briefly outlined below.

Binders preferably form a hard and durable film after drying. The pigments give the building color the respective color. In contrast, the solvents have the function of keeping the viscosity of the building color so low that the building color z. B. by brushing or spraying z. B. can be applied to a wall. By later evaporation or drying harden the building colors and adhere to the respective underground. Additives are substances that change the properties of the respective building color. Additives can change the degree of cure, the film crosslinking or the skinning of the building color.

Recipes for building paints are produced in small and medium-sized color batch sizes according to a wide variety of recipes. The preparation is often carried out for more than 50 years, preferably unchanged with the help of dissolvers, wherein the raw materials are fed to the production process of silos, or big bags and sacks of different sizes.

A dissolver is an aggregate for dispersive mixing of raw materials used in the paint and coatings industry. The dissolver can be designed as a disk stirrer. A dissolver is a technical term used in the German language in this field.

Each color quality and every single color is based on a specific recipe. The execution of the respective recipe requires z. B. a gradual addition, uniform distribution (dispersion) and mixing of various raw materials with water.

The recipe for each individual color is executed step by step and processed until the finished product is reached. This requires manufacturers of architectural paints the existence of numerous individual silos, in which the necessary for the respective color quality of individual components are stored. This is significant Purchase costs, operating costs and a large space requirement.

A wide product range and short order rhythms in the building paints business force production in comparatively small batches and often oppose an efficient production process.

In particular home improvement and craft companies expect a special variety of articles in terms of emulsion paints, silicone resin paints, silicate paints, dispersion silicate paints both for indoor and outdoor use. In addition, wood coatings, lacquers and glazes are required, which must be available at short notice, even in small and very small order quantities.

A well-stocked reseller keeps in his full color range regularly 500-2500 individual building colors ready.

Each of these products consists of a large number of individual raw materials. As the variety of articles increases, so does the number of raw materials required to produce them.

Another problem is the risk of contamination of the raw materials, the semi-finished products resulting from the production process and the finished products themselves. An additional problem is the long analysis times (24-72 hours) to determine the microbial contamination

In particular, the large variety of products and the product in small quantities makes a cost-efficient industrial color production of emulsion paints, enamels, and glazes often impossible.

procedures

Activities in the production of emulsion paints, silicone resin paints, silicate paints, silicate emulsion paints, wood coatings, paints and glazes are associated with a variety of physically demanding and dust-polluting work. The workers employed in the production of building paints have to carry heavy bags of raw materials on a daily basis, which leads to a high degree of illness in the factories.

The production processes are characterized by small and very small formulation approaches with a high proportion of physical work in particulate matter.

The respiratory tract of the workers employed in the production of building paints is burdened with raw material dust with approx. 94 kg per year on average. This can cause lung diseases and / or cancers.

Existing national and European occupational health and safety directives prescribe the wearing of respiratory masks in the construction paint industry, especially when dealing with powdered raw materials. However, this is often perceived as a nuisance by workers in day-to-day business and is therefore often bypassed.

In view of these complex procedures above, a simplified mono-slurry has occasionally been used in the prior art for the sake of simplicity. The term slurry will be explained below. This mono-slurry was supplied by suppliers of the paint industry and consisted of calcium carbonate (CaCO ₃ ) as the main constituent and filler;
Furthermore, the mono-slurry water, wetting agents, dispersants, defoamers and means for preservation during the transport time on. This mono-slurry included the calcium carbonate (CaCO ₃ ) about 3 microns in a 75 (wt)% formulation. For the rest, however, it remained with the individual components shown above, which were further processed in the manner shown to building colors. As a result, this concept of mono-slurries has not gained acceptance in the paint manufacturing industry, and has not provided any improvement in terms of water balance regulation.

raw materials

For the preparation of each recipe for building paints, varnishes and glazes a variety of individual raw materials is required, preferably as a powder z. B. mixed together in dissolvers and preferably dispersed in water.

The production of a color quality or a hue is always associated with its own production approach. For the production of the respective color, each recipe must be processed taking into account the type, quantity and quality of each raw material, raw material for raw material to the production of the finished product. This process is repeated at every production approach.

With the increase in the variety of varieties also increases the number of production approaches required, whereby the production of emulsion paints, silicone resin paints, silicate paints, Silikatdispersionsfarben, wood coatings, paints and glazes is often uneconomical and leads to higher final production costs and longer delivery times.

contamination

The contamination of end products or production plants represents a significant risk for the building paints manufacturer during the manufacturing process and storage. In the case of contamination, entire batches must be regularly destroyed and in extreme cases even the production facilities and their pipe connections thoroughly renovated or completely renewed.

So far, microbiological measures have been limited primarily to the attempt to detect the existence of bacteria by sampling samples on a nutrient medium. However, such an analysis takes up to 72 hours for a very long time. However, the analysis only provides information about the presence of bacteria, but not their activity.

In case of detection of bacteria, preservatives must be added to kill the bacteria. Since it takes up to 72 hours between taking the sample and detecting the germs, the bacteria have generally multiplied so much that a comparatively large amount of preservative has to be added in order to save the end product or the production plant.

A timely, microbiological analysis that would make it possible to control bacterial growth at an early stage by using only small amounts of preservatives is not possible in this way.

Known measures for the prevention of microbial contamination have so far been limited to as pure as possible storage of the raw materials.

Binders and additives are usually stored in closed tanks or containers, while the powdery raw materials are stored as long as possible in a dry state.

As part of the production process powdery raw materials are known to be transferred into a liquid phase. This creates temperatures of 25 to 35 degrees Celsius. However, moist and warm environments are ideal growth conditions for bacteria.

For this reason, it is the aim of a conventional manufacturing process to produce each recipe as possible in one go and to keep a temporary storage of liquid raw materials as short as possible.

Due to these limitations, the use and storage of standardized semi-finished products has hitherto been associated with high risks.

task

The invention has as its object to provide a cost-effective manufacturing process that ensures the end user a wide range of individual color products and reduces the required delivery times.

The invention also has the task of providing a production process preferably for emulsion paints, silicone resin paints, silicate paints, silicate emulsion paints, wood coatings, lacquers and glazes, which in addition to all known functions of conventional production methods additionally enables efficient, fine dust reduced raw material handling.

In the following, the dispersion paints, silicone resin paints, silicate paints, silicate emulsion paints, wood coatings, lacquers and glazes are generalized but in no way exclusively referred to as building paints.

A further object of the invention is to be able to reduce the required number of formulations for producing a large variety of variants of the building ink manufacturer, in order thereby to streamline the manufacturing process and to be able to reduce the production costs.

The invention moreover has the goal of being able to work over long distances of the production process with a small number of standardized semi-finished formulations in order to produce the variant variety by adding different quantities of quality-determining raw materials, such as binders or titanium dioxide in liquid form, only in the last production step.

An additional object of the invention is to provide a microbiological analysis method which enables a timely control of the microbial condition and provides for each raw material or mixture of raw materials used an individual procedure for a microbial stable storage.

A further object of the invention is to provide a method by which semifinished products can also be used at decentralized locations without having to install expensive and expensive investment silos in advance.

In addition, the invention has the object, the risk of contamination of the Products preferably semi-finished products already during production, storage or subsequent transport z. B. in tanks as far as possible.

It would be desirable in the manufacturing process to provide a base intermediate which is the basis of the further manufacturing process for all, or at least most, of the colors and builds on the quasi-cascade further manufacturing operations, which in turn lead to further processed intermediates, which in turn will be the basis for further diversification in the manufacturing process and it would be particularly desirable if the base intermediates were already available for commercialization, such as simple or simpler color applications.

The previous procedure for the production of building paints, which requires a continuous sequence of manufacturing processes under the basis of individual product formulations to the final product, does not allow a flexible location-independent, modular processed and feasible production of individual components.

Previous production methods prove to be disadvantageous in many cases, since a building paints manufacturer who wants to export his colors abroad usually has to pay very high freight costs, which become prohibitively expensive with increasing distance. As an alternative to export, the building paints manufacturer can set up its own production site in the destination country, which, however, entails high investment costs.

For the color to arrive in a microbiologically flawless condition at the reseller or end user, it requires the use of relatively high-dose anti-microbial agent or the use of preservatives.

It is therefore a further object of the invention to make the production of architectural paints more flexible in order to enable any steps to produce the final product to be carried out at a location outside of the paint manufacturing parent plant.

solution

The object is solved by the features of claim 1 and independent claims. Preferred embodiments are listed in the subclaims.

Summary of the invention

recipe architecture

Based on the present invention, a recipe architecture is first used. This consists in the use of previously developed formulations for product families, rather than individual product formulations. This enables a harmonization of raw materials across the entire recipe architecture. Another advantage is the possibility of significantly reducing the number of raw materials.

Furthermore, this results in a synergy in the formulation structure.

According to the invention, fewer but multifunctional modules are created.

The recipe architecture leads to universal, d. H. in different individual recipes, usable raw material semifinished products instead of single raw materials. The development of raw material semi-finished products as a combination of raw materials is understood to be the greatest, if possible the greatest possible, common multiple in order to be able to use this combination for further processing into a large number of final formulations.

At the same time, this modular concept makes it possible to produce incomparably larger batch sizes, because each batch produced can, on the one hand, be conveyed to a higher degree of refinement and, on the other hand, can already be a marketable product, which is particularly suitable for less demanding types of use.

Furthermore, the process times are significantly reduced by this modular system.

Raw materials have not undergone any further processing as primary raw materials. Secondary raw materials refer to those raw materials obtained from a recycling process. These are uniformly referred to as raw materials in the context of the present invention.

These include, in particular, pulverulent or other ground raw materials.

The raw materials are no longer stored in silos as usual until they are fed into the processing process at a later date. Preferably, they are further processed by means of just-in-time delivery by the raw material suppliers directly and without intermediate storage.

Modular platform manufacturing concept

In anticipation of the individual points presented below, the modular platform production concept will first be presented in its basic mode of operation.

Insofar as the term "slurries" and the term semi-finished product are discussed below, for reasons of clarity, a more detailed explanation of these terms and their delimitation from each other will be presented after the basic mode of operation has been described.

A basic idea is that each of the modules described below, which in principle correspond to intermediate steps and also lead to intermediate products, form the basis for marketable color products. Preferably, even the first modular platform, which is the basis for a further production of colors and further finishing steps, should already lead to a marketable product.

Unless otherwise stated, the indefinite article "a" or the particular article "the, the, the" or a plural form thereof, is not linked as a numeral unless specifically stated. The number of raw materials used and their quantity remains reserved to the expert, who will also vary the choice depending on the specific building color.

These individual modular platform recipes correspond to modules implemented in process steps, whereby these modules also interlock in the entire production process and can equally use individual raw materials, for example.

Thus, with the platform formulation according to the invention, a methodology for formulation in the context of a paint production process is made available in order to prepare formulations for building colors from standardized, universally applicable, liquid semifinished products rather than from successively processed individual raw materials.

Semifinished products, hereinafter also referred to as intermediates, are preferably formulated in such a way that they can be used both as a salable end product or as a basis for the refinement of a higher-quality end product.

With the invention economies of scale are achieved with a large variety of end products by using largely standardized semi-finished products and the variety of varieties produced only in the last step by admixing quality-determining raw materials and additives (so-called. Customization).

This makes it possible to design the production of building colors modular so that liquid semifinished products, in particular liquid powder semi-finished products are stored at locations outside of the main paint factory and further processed there by mixing with binders and additives to final products. Of course, it is possible that the colors are made entirely in the main paint making plant.

This modular method of production is made possible in a special way by carrying out the method steps which presuppose a dispersion process in the main paint production plant. In the locations outside of the major paint production plant, it is sufficient that the liquid semifinished products are stored in tanks, for example, and only have to be mixed there with the other constituents to be added, without the need for a more technically complicated dispersing process.

This modular platform recipe or production works particularly well, even if the raw materials are prepared in a modular manner and processed further. The use of cocktails and premixes is well suited for this process. The modular raw material composition is adapted to a corresponding modular plant alignment. It only requires a few system devices that are tuned to the respective modular raw material batch, so that it does not require any required adjustment of the system parts, as in the conventional manufacturing concept, in which a variety of different raw materials must be processed sequentially depending on the desired color, which inevitably requires a continuous adjustment and readjustment of the plant components during this respective production process. By using modular raw material compositions in this process, ideal chemical and physical properties of the product are created, which are accompanied by a consistent, repeatable quality.

This modular platform formulation or production allows new architecture formula. Harmonization and reduction of raw materials is made possible. The result is functional intermediates. The standardization is much higher compared to the conventional method of production. In particular, however, it enables an adaptation to customer requirements and a tailoring to specific requirements (only) in the respective last method step, depending on the desired goal.

Just this is also a flexible, satellite-like production and distribution possible, with the particular last step, for example in satellite outward, z. B. foreign, production and / or distribution units can be done so that the main modules can be realized in one place, but not necessarily. Figuratively speaking, this foreign location can be called a satellite location; Of course, it can also be located near the main paint factory.

As a result, an unknown flexibility is achieved by the products that result from the implementation of the modular formulation concept, on the one hand can be sufficiently produced and the individual finishing (so-called customization) can be done quasi customer-specific. Delivery problems that typically arise due to the necessity of processing the individual process steps according to the conventional production concept are largely excluded. As will be explained below, highly effective production and distribution, which can control the removal of germs, is made possible by real-time analysis, which enables a quantitatively clearly limited use of antimicrobial substances. It goes without saying that this described system is also much cheaper at a constant, high quality, especially as far as the overall hygienic conditions, as in the conventional production method.

Further processing and refinement differ in the sense of the present invention in that a refinement essentially strives for a higher quality level, while further processing means the rather basic process steps.

Forwarding the slurries is understood herein not only the transport of the same in a line system within the main plant but also the further transport of the same to a satellite location.

The above summarized reproduced modular formulation conception also corresponds to a configuration of a production facility for such building colors oriented thereon.

The plant for the production of architectural paints then has at least one process tank, at least one binder tank and at least one additive tank.

In addition, the plant for the production of building paints preferably has at least one storage tank. This storage tank is used to hold one or more slurries and / or the inclusion of a semi-finished product. This slurry and / or semi-finished storage tank is hereinafter referred to for the purpose of standardization as a storage tank.

The function and composition of the slurries will be discussed in more detail below.

Since the process tank is also associated with a slurry, its differentiation from the at least one storage tank in the context of the present invention is based on the fact that the process tank is associated with a dispersing process and optionally with a mixing process, while the term storage tank for a tank stands, which is not related to a dispersion but with a mixing process.

In a preferred embodiment of the system, at least two process tanks are used.

Furthermore, the system preferably has a buffer tank and / or a tank for other components in small quantities z. As cellulose and / or a tank for more, in particular powdered components.

In a further embodiment, the plant also comprises an input device with which the raw material or raw material mixture is taken from a silo tanker. Preferably, the removal is carried out by placing a vacuum, wherein the vacuum is preferably generated by the high rotational speed of a rotor having a rotor device.

The rotor may be arranged in the dispersing device explained below.

But it is also possible that a separate suction device is provided.

Furthermore, the system lines, preferably pipe connections between all tanks, associated valves and control technology to exchange between the process tank (s) and the at least one storage tank semi-finished products as needed and if desired in the respective target tank, be at least one process tank or storage tank can process these to either higher value semi-finished products or to a final product.

The plant preferably further comprises one in the main color production plant existing agitation device, by which a mixing device is understood, which ensures that settling of (already dispersed) substances and / or (already dispersed) liquid takes place in a tank. This agitation device is preferably a jet mixer.

This agitation device can be a functional and / or constructive component of the at least one process tank and then comes into operation when the already dispersed slurry is further processed to a next higher processing or refining stage. This further processing takes place by adding and mixing the slurries with binders and additives to optionally end products.

The agitation device can also be a functional and / or constructive component of the at least one storage tank. In connection with the at least one storage tank, it is thereby made possible that liquid powder semi-finished products can also be stored at locations outside of the main paint factory and further processed by mixing with other substances, in particular with binders and additives to possibly end products.

Preferably, the rheology is adjusted in this context, for. B. by adding a thickener in the form of cellulose. It is about an addition of 0.1-4 wt .-% of such thickener systems into consideration. Other thickener compositions, eg. As polymer thickener or the like as in the EP 0 682 094 are also considered

In addition, the plant has an analyzer device for carrying out a real-time analysis of the microbial contamination, preferably of liquid raw materials or of combinations of these and semifinished products.

The analysis device is used to check the hygiene status of the liquid raw materials or the combinations thereof, in particular the slurries, as well as the semi-finished products with the aim to store them for subsequent further processing germ-free or transport to another location outside of the main paint factory and store there can.

Further preferably, the raw material or raw material mixture is transferred at the beginning of the process of silo tank first in a buffer tank, z. B. sucked or blown out. This buffer tank is used to compensate fluctuating flow rates during discharge.

The extracted raw material or mixture of raw materials is therefore fed either directly from the silo tank or via the buffer tank to a tank system.

This tank system, which will now be described in a coherent and anticipatory manner, comprises at least one, preferably two or more process tank (s).

In the at least one process tank, dry powder or a dry powder mixture is processed to a liquid slurry. This is done by adding an appropriate amount of liquid, especially water. The slurry is described below.

For this purpose, a dispersing device is also provided, which can be arranged in a spatially different from the process tank or the process tank dispersing chamber.

The dispersing device has a rotor-stator device for this purpose.

The rotor / stator principle is known as such. The rotor and stator may each be constructed of a plurality of rotor or stator rings (steps) which are radially grooved, serrated and / or drilled, vary in number, shape, width, depth and orientation, and which are both plane-parallel and stepped can be constructed.

The dispersing device is assigned functionally to the process tank. For this reason, the process is also described below in such a way that, in this process tank for the preparation of the slurries, the raw materials introduced into this process tank, directly via the dispersion chamber, are dispersed. Water is added to the mentioned raw material or to the raw material mixture. In particular, titanium dioxide, filler and an additive are dispersed in this process tank. This results in a slurry.

For this purpose, between the optionally spatially arranged away from the process tank dispersing device and the process tank in which the slurry is located, preferably a circulating process control via lines which are arranged between the dispersing device and the process tank. In that regard, preferably, there is a continuous, circulating, recurrent dispersion.

But it can also be dispensed with such a circulation-like dispersion. According to the invention, however, it is necessary that a dispersion takes place for the preparation of the slurries.

The following is an explanation of the situation in which only one process tank is present in the plant, the dispersion being assumed to take place:
The slurry can fill the process tank in different volumes.

If the process tank is approximately completely filled with the slurry, further processing of the slurry can not take place in this process tank, as far as this further processing would consist in the addition and mixing of further raw materials. In this case, the slurry on the one hand in its capacity as a standardized, universally applicable, semi-finished liquid, be a salable end product and be filled accordingly in transport or sales containers. On the other hand, in this case, the slurry would preferably be able to be forwarded completely or partially to a storage tank located in the main plant by means of a pipe connection.

With only a partial forwarding of the slurries to the storage tank now creates free volume for the purpose of Weiterverabeitung the slurries in the process tank, as described above which is done by adding binders and additives and by mixing the slurries with the same.

If, on the other hand, the slurry is partially or completely transferred from the process tank into the storage tank, the slurry is then further processed at a subsequent point in time. For later further processing, the slurry is pumped back into the process tank. The raw materials required for the subsequent further processing of the slurries, such as. B. binders are introduced directly into the process tank, in which the subsequent further processing takes place.

But it would also be possible to fill the slurry from the process tank for its further transport and then store the slurry at a location outside the main plant (satellite location) and further processed there by mixing with binders and additives. For this purpose there is no need to continue the dispersion. The mixture can be carried out by a previously described agitation device.

Of course, the above procedure of further processing in the process tank is only possible if it is not completely filled with the slurry from the outset, so that there is sufficient volume for the addition of further constituents.

The situation of the system is described below, in which more than one process tank, z. B. two process tanks, are present: The two process tanks can each fulfill the same tasks functionally identical. Preferably, a dispersing device is provided in a dispersing chamber between the two process tanks in a functional, but in particular spatially separated manner. Again, the dispersing device comprises the rotor / stator device as described above. Of course, another type of dispersing device is also possible. The word "between" is not to be understood exclusively in the sense of a spatial arrangement, but rather describes the operative connection of the dispersing device with the two process tanks.

For this purpose, the dispersing device is connected by pipes to the process tanks. It can, as described above, take place a circular, continuous dispersion. The circulatory dispersion may be related to one or both process tanks. This means that the dispersing device can be switched so that it either communicates with only one process tank or with both process tanks. As a result, as also described above, the slurry is produced from a dry powder or from a dry powder mixture and a liquid, optionally including further constituents.

Between the two process tanks, a pipe, in particular pipe connection, is arranged, through which the slurry can be pumped, preferably pumped, from one process tank to the other or vice versa as required.

The arrangement of two process tanks allows a particularly flexible design of the modular manufacturing process.

If, for example, only half of the process tanks are filled with the slurry, it is possible to carry out either identical or different further processing or finishing by adding further process materials in both process tanks, depending on which type of building color is to be produced. These substances added to the slurry may be, for example, a binder dispersion, additives, preservatives, thickener systems for adjusting the rheology, defoamers, etc. Since a dispersion has already taken place, it is no longer necessary for this further processing. A mixing process by means of an agitation device is sufficient for this purpose.

After production of a composite of this type further intermediate or end product emptying takes place in transport or sales containers.

But it is also possible that only one of the two process tanks is filled with the dispersed slurry. In this case, a portion of the slurries from this process tank the other process tank by means of a arranged between two process tanks line, z. B. pipe connection, are supplied. In this case, in the process tank to which the slurry has been supplied, further processing thereof may be performed to a next finishing or finishing stage according to the above-mentioned explanations.

A residual slurry remaining in the process tank leaving the slurry, no matter what volume, can either be emptied as a semi-finished product for the purpose of sale. In this case, the semi-finished product is practically the salable end product. But it is also possible that the rest of the slurries is transferred to another target tank, z. B. in a storage tank at the main location of the color production Hauptwerks, by means of which then at a later date further processing takes place. The forwarding to the storage tank is preferably via a line, in particular pipe connection. As target tank but also a storage tank outside the main works (satellite location) comes into consideration; In this case, the dispensing process tank would be emptied and the slurry be filled into a transport container.

As far as above is spoken of the further processing of slurries in the one process tank or in both Pozesstanks, it should also be noted here that the further processing or refinement is based on a largely standardized semi-finished product in the form of slurries and in the last step by admixing quality-determining raw materials and additives each desired end product is achieved.

In a preferred embodiment, the at least one process tank can be designed so that a removal of the slurries and / or the further processing product for the purpose of analysis for the presence of microbial contamination is possible. Further details are presented in this respect in connection with the storage tank, which apply mutatis mutandis to the process tank.

Both process tanks can be structurally designed as two separate, independent process tanks. They are structurally separated from each other in this case. But they can also be arranged in a parent container system and thereby separated from each other by a partition. In addition, there is the possibility that both process tanks are functionally and constructively designed as a unit and that the dispersion for producing the slurries takes place by means of a dispersing device arranged separately therefrom. In this latter case, the dispersing process is preferably switched on in phases. Both process tanks can thus be used independently of each other in all the situations described above.

After the process tank system has been explained in summary, it will be discussed below on the other parts of the plant and their function in the context of the manufacturing process for building colors.

As shown, the process tank is either directly or indirectly, z. B. fed via a powder container, dry powder for the purpose of processing to a slurry. This dry powder may contain a raw material or comprise a raw material mixture.

Depending on the recipe are the least one process tank next to the extracted, mentioned raw material or in addition to the raw material mixture, or was taken from the tank car, other recipe ingredients, such. As thickener or titanium dioxide or kaolin or other powdered ingredients supplied. This can be done by, for example, discharging the cellulose or the other pulverulent components from one or more further containers, in particular pumped out or sucked off and transferred to the at least one process tank.

Below, the system and the process situation will now be described, as far as one or both process tanks the relevant slurry was passed directly or indirectly to at least one storage tank.

Immediately or indirectly in this context means that the storage tank is present either in the main plant of the paint manufacturing process and / or in a location outside the main plant (satellite location). The further processing of the slurries described below in a storage tank is in principle the same, regardless of whether the further processing takes place in the main plant or in a location outside the main plant (satellite location).

In this one or more storage tank of the slurry is stored and serves for flexible further processing due to the illustrated modular platform formulation.

Even outside the location of the main plant of the paint manufacturer, the storage tank is used to store the slurries.

To a further refinement outside the location of the main plant is in particular a separate mixing tank used in which all required modules are merged. The mixing of the substances takes place by means of a stirrer. A repeated dispersion at a location outside the main plant of the paint manufacturer is therefore no longer necessary.

If necessary, however, a storage tank can also be configured in such a way that the aforementioned process steps can be carried out in itself. However, this requires a relatively rapid processing and cleaning there, because in particular the addition of binder leads to adhesion of the semi-finished product on the wall of the storage tank.

Regardless, the storage tank has a stirring device by means of which the slurry or the semifinished product stored there is stirred continuously or periodically in the storage tank.

The stirring device can be arranged on the outside of the storage tank and protrude into it by means of suitable construction with the agitator.

This storage tank further comprises a device, for. As a valve, for removal, so that its contents can be fed to a real-time analysis on the microbacterial consistency.

The system further comprises a device for carrying out an analysis for determining the microbiological state of the slurries and / or the semifinished product, in particular of those slurries, which is stored in the at least one storage tank. After appropriate sample preparation, the analysis device carries out a so-called hygiene analysis. The device is used to analyze whether and to what extent microbial contamination of the slurries and / or semifinished product is present; If yes, the total germ count is preferably determined and displayed. The device is designed not only to detect and display the microbial contamination as such, but also to carry out an activity analysis of the germs.

Based on the determined results and a method for the interpretation of the measurement results, it is possible to preserve the recipe individually. This needs-based supply of preservatives is harmless to human health and the environment. The real-time analysis enables a fast reaction and prevents further bacterial contamination through the early addition of selective biocides.

After this summary, the individual process steps, components and devices will be discussed.

slurry

As stated, the raw materials in the color production are preferably brought together by suction or blowing out of a container, in particular a silo truck of raw material suppliers with preferably specially selected, a few other raw materials and processed to preferably liquid media, the so-called slurries.

The raw materials and, if desired, further fillers are to be transferred (dispersed) at the very beginning of the process into a liquid phase, so that they merely have to be mixed together in the remaining process and no longer have to be dispersed.

A slurry denotes a heterogeneous mixture of at least one fluid, in particular a liquid and further solid particles, which are distributed in the liquid.

The slurry refers to a suspension or dispersion in which solid particles are distributed in a liquid. It is a well-known in the German language term in this field. Conventional terms in the German language are, for example, slurry or dispersion mixture.

In particular, a slurry may be referred to as a liquefied powder, which may comprise calcium carbonate (CaCO ₃ ), kaolin, talc, for example as a constituent in addition to the liquid.

A premix slurry may consist of various raw materials and may further comprise calcium carbonate (CaCO ₃ ), kaolin, talc.

The term of the mono-slurry has been explained in the context of the explanation of the prior art.

The preparation of the liquid slurries takes place in the process tank, preferably with dispersion and using dry powder or a dry powder mixture and one of a liquid, in particular water.

The dispersion takes place by means of at least one dispersing device, wetting agents and antifoams being added during the dispersion.

It is also conceivable to produce the required amount of slurry separately in at least two preferably connectable process tanks.

The slurry according to the invention becomes a fully storable and transportable, preferably semi-finished product, which can be further processed economically even in large batches if, for example, it is admixed with additive and a favorable binder for a low-cost formulation, in particular by means of the agitation device. For example, in this particular embodiment, the slurry may be used for simple applications, e.g. As a ceiling color, are used, so for applications that are typically exposed to less stress than other building colors that must be suitable for about walls or floors.

Apart from this situation, the slurry will above all be the basis for further processing or upgrading to higher intermediates or end products.

In that regard, the slurry can be negatively delimited to a final product by the fact that, with the exception of the aforementioned example, in principle it lacks binder.

In the closed system, the combined raw materials are environmentally friendly and cost-effective, preferably processed into liquid slurries.

The suspension of the slurry tends to phase separation, in which the solid particles do not form a material connection with the liquid, but settle in the receiving the slurry container, preferably a tank or silo. The phase separation separates the solid particles from the liquid.

To counteract the phase separation, the solid particles with the aid of mixing units, such as. As stirrers, dissolvers, jet mixers or wet mills distributed within the liquid of the slurry.

Semi-finished products

The term intermediate is used herein synonymously with the terms semi-finished or semi-finished product.

As semi-finished products in the context of the present invention, for example, the following material compositions, after dispersion, ie after preparation of the slurries are considered.

It will now be a closer explanation of the term semi-finished products, especially in contrast to the above-mentioned concept of slurries.

A semifinished product is assumed, for example, in the case of a composition of a mono-slurry and a premix slurry, for example a calcium carbonate slurry with a titanium slurry.

A semi-finished product is assumed in a premix slurry with other raw materials, such as calcium carbonate (CaCO3), kaolin, talc.

A powder premix can also be regarded as a semi-finished product in the sense of the present invention, since it contains various types of powder.

The case mentioned in the context of the discussion of the slurry that added to this additive and about a favorable binder can equally be regarded as a semi-finished product in the sense of the present invention.

A semifinished product is also present if, based on about one of these aforementioned cases a next higher quality level in the context of further processing or finishing is achieved, such as by adding and mixing of kaolin, titanium oxide, calcium carbonate, höherwertigerem binder, talc or china earth (clay).

Customization

If, for example, a further substance or further substances are added, in particular admixed, to this aforementioned further processing stage, this can already take place within the framework of the so-called customization.

Mention should be made, by way of example only, the addition of selected titanium oxide to influence the opacity of the paint or the addition of selected binder for influencing the suitability of the color for the exterior or interior of a building.

The customization has already been mentioned in various contexts. It should also be mentioned that such is also achieved by alternative or supplementary addition of at least one additive. One thinks of the addition of an additive, which has a fungicidal or water-repellent effect.

• – Pulverförmiger Einzelrohstoff oder Pulvervormischung (Premix),
• – Überführung des Einzelrohstoffs oder der Pulvervormischung in eine flüssige Phase (Slurry) durch Dispergieren,
• – Beimischung von Additiven in die flüssige Phase, um ein mit chemischen oder physikalischen Funktionen veredeltes Halbfabrikat zu erhalten,
• – Bevorratung des Zwischenproduktes gemäß den beiden vorerwähnten Unterpunkten,
• – Vermischen der Produkte gemäß den Schritten 2 und 3 dieser Zusammenfassung mit Bindemittel und weiteren Additiven zur weiteren Veredelung (höher veredelte Halbfabrikate)
• – Endveredelung durch Beimischen qualitäts- und variantenbestimmender flüssiger Rohstoffe zum fertigen Produkt.

The above-described steps can be summarized again as follows:

• - Powdered single raw material or powder premix (Premix),
• - transfer of the individual raw material or the powder premix into a liquid phase (slurry) by dispersing,
• Admixing of additives in the liquid phase in order to obtain a semifinished product finished with chemical or physical functions,
• - storage of the intermediate according to the two aforementioned sub-items,
• - Mixing of the products according to the steps 2 and 3 of this summary with binder and other additives for further processing (higher finished semi-finished products)
• - Finishing by adding quality and variant-determining liquid raw materials to the finished product.

The end product can thus be produced optionally already in step 3 by final finishing (mixing of quality and variant-determining liquid raw materials), if the sales volume allows production in large batches. For smaller sales volumes, only partial quantities are processed and bottled for the final product, while the remaining quantities are stored as semi-finished products for later refining in storage tanks.

Optimization of the water balance of filler semi-finished products

The use of semi-finished slurries, preferably in liquid form, means that many times more water is introduced into the production process than would be required in the respective finished product.

To regulate the water balance, the fillers and / or platform formulations in slurries are preferably combined with regard to the morphology and the particle size of the end product in the at least one process tank in such a way that a high packing density can be achieved.

Due to the high packing density, the water content in the slurry can be reduced to an optimum level.

Process engineering parameters

For the individual raw materials and intermediates, the process parameters are determined. These include viscosity, temperature, speed of the dispersing unit, dispersion time and other parameters which are familiar to the person skilled in the art. To maintain and optimize the process parameters, a general processing sequence of the raw materials and intermediates is preferably maintained.

dispersion

The fillers or raw materials are dispersed at the beginning of the process in at least one process tank. This is preferably done only once. Dispersion is an essential aspect of the present invention for the preparation of slurries.

Dispersants are preferably added to the at least one process tank, which wet, sludge and float the solid particles with the liquid. In the slurried state, the solid particles are dispersed in the liquid phase.

Dispersants are additives that allow or stabilize the dispersing, ie the optimal mixing of at least two, not really immiscible phases (substances).

The fillers are subsequently further processed only in liquid form as slurries or stored until further use in tanks, preferably in storage tanks in and / or outside the paint manufacturing parent plant.

With the help of the combination of solid and liquid raw materials into a slurry, the number of components and processing stages to be processed is considerably reduced in the production of building colors.

With the help of slurries, end products can be modularly built in building paints. The color modules can be mixed together in the form of platform formulations as needed.

The dispersion preferably of the raw materials takes place during the process of manufacturing the building color only once at the beginning of the manufacturing process.

Until further processing of the slurry, the blended raw materials are stored in at least one storage tank. The slurries are only mixed in the further production process.

Further dispersion in a later stage of the process is not required.

The dispersion and the processing of the raw materials into a slurry takes place in at least one process tank during the feed process (simultaneously) preferably from the silo tanker.

The need for an additional cost-intensive silo and powder handling technology is thus eliminated.

microbiology

The manufacturers of paints must generally keep an eye on microbiological aspects. Rock-milled fillers, for example, naturally contain bacteria. Also, for example, the process water provided by the local water companies may contain germs, to name just a few examples.

The use of preservatives or anti-microbial substances is legally very limited. Therefore, close microbiological monitoring of slurries and intermediates takes place.

The monitoring and preferably the analysis with presentation of results takes place in so-called real time, d. H. the results of the monitoring can be available no later than 2 to 3 hours after the sampling, so that a very finely dosed supply of antidotes (qualitatively and quantitatively) is possible.

The analytical device used in accordance with the invention is designed such that it not only determines the amount of microbes that may be present. Above all, it is designed in such a way that it also records the activity of the microbes, in particular their potential for multiplication. It is precisely through this combinatorial analysis technique that it is possible to determine the actual microbiological state and the expected microbiological development of the liquid slurries and / or the semifinished product. This is a prerequisite that a short-term response to this condition is possible and rapid dosing of an anti-microbial agent with the least possible but sufficient amount.

These timely, post-sampling measures allow the use of preservatives and / or antimicrobials far below the levels allowed by law - as much as needed, but not as much as possible.

At the same time, this is accompanied by a significant improvement in terms of storage longevity and universal usability.

logistics

Since, as explained further dispersion is no longer necessary, but the slurries or intermediates are subjected in the final processing only a simple mixing process, a continuous production or production on-demand is possible.

Storable slurries can be transported over long distances in tank trucks and enable storage and further processing at decentralized locations, without the need to have a fully-fledged paint factory with silo facilities. This means that cost-effective capacities for the production of paints can also be built up in remote locations within a few weeks.

Detailed description of the invention

Platform recipes / recipe Architecture

In the preparation of a platform recipe, evidence of the suitability of the raw materials for processing into functional products, preferably of a semi-finished product or of the finished product and proof of the mutual compatibilities for physical and / or chemical properties, is to be provided. At the beginning of these considerations, this proof is again conducted under laboratory conditions.

For this purpose, the raw materials are tested in combination with other raw materials according to physical and / or chemical and / or performance characteristics.

Over a given period of time, an examination of the functions and the stability of the platform recipes takes place.

The hypothetical platform formulations are tested under laboratory conditions on the miniature system.

The formulation of the platform formulations and the determination of the process steps required for the preparation of the platform formulation are preferably determined on the basis of test series and / or measurement series.

In addition, defining the required functions of the respective product in order to make the platform formulation for a wide range of products, preferably a semi-finished product or the finished product can be used.

Platform recipes are created based on the content you want, the processing steps required, and the process parameters.

With the help of the platform formulations, the raw materials are first processed into standardized functional semi-finished products. The platform formulation preferably comprises powdery and liquid raw materials, preferably with the addition of Fluids, especially water are mixed together to form a slurry.

The use of platform recipes makes it possible that the previous individual formulations in the manufacture of building colors can no longer be produced from individual raw materials, but from functional formulas that can be used universally in many final formulations.

The mixing of individual recipes from a variety of different raw materials can be omitted.

The semifinished products designed as platform formulations are formulated in such a way that they can be used as the basis for a large number of different end products.

As a result, a standardization of the platform recipes is largely achieved, resulting in a particularly economical method of production.

Due to the universal applicability for many final formulations, production approaches for platform recipes and semi-finished products in large batches and batches can be produced economically.

The number of otherwise required for the preparation of the respective individual recipes handles, and the number of associated error sources can be significantly reduced, which can simplify the entire manufacturing process.

The quality characteristics preferably describe the wet abrasion, the hiding power of the paint, the gloss level, the weather resistance and the processing property. It goes without saying that the preceding list is meant to be exemplary only and in no way exclusive.

In the following, it is determined which raw materials are required in order to be able to influence predetermined properties.

Combining the required product features and distributing to a reduced number of platform recipes results in the widest possible range of uses.

Hypothetical combinations of raw materials are formulated on the basis of individual commodity characteristics.

Economical and supply-relevant aspects influence the formulation of the raw material combinations.

From a limited number of platform formulations can thus a wide variety of architectural paint end products, preferably emulsion paints, silicone resin paints, silicate paints, Silikatdispersionsfarben, wood coatings, paints and varnishes are made.

A comparison with the number of individual formulations comparatively small number of platform formulations can be used for almost all end products. As a result, an economical production of platform formulations is possible even in large batches.

A combination of different slurries to form a platform recipe preferably takes place in closed systems.

The respective slurries are added according to the desired quality characteristics in different qualities.

In order to produce a slurries based on at least one platform formulation, preferably pulverulent raw materials are sucked off directly from the delivering tanker without being diverted via a silo or any other powder delivery and further processed into a liquid phase.

Depending on requirements, raw materials are delivered in the required quantity in tank trucks or in containers of various sizes and introduced directly into the process tank. Material losses due to dirt-intensive cutting and emptying from big bags or sacks are avoided, since the exhausting and extremely dirt-intensive mixing of individual color formulas from sacks or big bags, for B. omitted in dissolvers.

The platform formulations are stored as semifinished products preferably in slurry tanks and processed in a process tank to finished products.

The use of platform recipes and the incorporation of slurries make it possible to replace the "muscle worker" with a "machine operator" who can conveniently control the production of building colors using a touchpad computer.

In this way, a high number of variants and short delivery times can be ensured.

This is all the more true for locations in different countries. Regional preferences can be made basic by simply mixing in-country additives Platform recipes are implemented quickly, without the need for separate production lines in the individual countries. For example, German consumers prefer looking for the building color "white" an almost bright polar white.

In France, the same customer would rather prefer a soft creamy white.

Similarly, the end user in Germany prefers a matt wall paint, whereas the English end user would prefer a glossy wall paint.

The use of platform formulations has the advantage that the production lines can be considerably streamlined, whereby the space requirements of the production facilities can be reduced.

Existing premises or rented standard warehouses can usually be used for the use of platform formulations without significant structural changes.

If, on the other hand, an extension of the production lines were required according to the traditional model, this would require additional investment for the expansion of the raw materials warehouse, in particular for silo facilities or other dry storage facilities for powder raw materials.

The platform formulations are at least operational throughout Europe, since all Euronorm quality features can be represented by dosing the appropriate functional platform recipes and meet the strict requirements for the use of preservatives.

At this point, the benefits of using the platform formulation could be demonstrated by way of the following example.

For the production of 40,000 t building color in a given variety of formulations about 15,000 approaches were required by conventional methods. By focusing on recipe platforms, the processing capacity of the new plant can be fully exploited and the number of approaches reduced to just over 1,500.

The smaller number of approaches saves considerable process times compared with the conventional production method, in particular during set-up and transport processes, cleaning processes, test times.

The production and storage of large-scale platform formulations is considerably more resource-conserving than the conventional manufacturing process and is able to achieve savings in terms of the following parameters, namely energy, raw material, recipe fading, paint sludge disposal, packaging material, conservation preservation.

Another advantage of the use of platform formulations is that a variety of building color end products in the form of emulsion paints, silicone resin paints, silicate paints, dispersion silicate paints, wood coatings, paints and glazes can each be mixed together from the same slurries.

Depending on the intended use, these modular colors can already be used as final products and delivered to commercial resellers. But they can also serve as a modular basis for further processing into higher quality end products.

Based on the platform-specific recipe modules, it is also possible to consider customer-specific requirements. On the one hand, the same product state can go as a finished end product in the delivery to the reseller and on the other hand serve as a modular basis for further processing, in that specific customer requirements can be met by admixing (and not dispersing) additives.

The modular production process makes it possible that any last, custom process step does not take place in the parent plant of the manufacturer of building colors. Rather, it is conceivable that the last customization of the building color to the specific needs of the end user z. For example, at a remote foreign location, such as the headquarters of a commercial reseller, for which customized end products are to be made available. This latter aspect is therefore also to be considered in the subsection on logistics mentioned below.

The product variety desired by the customer, the commercial reseller or the end user is only realized in a final method step in the production of the color finished product. For this purpose, the prefabricated platform recipe from different storage containers individual additives and other additives such. As paint aids, imitators, catalysts or emulsifiers in different mixing ratios.

The tint of the slurry can be made according to individual or regional color wishes of the customer.

In addition, for example, the addition of preferably special additives for a special mold protection or the admixture of Styrofoam particles for a special heat effect provide.

Individual DIN quality features such as As a special coverage, a special Naßabriebsbeständigkeit or a special gloss level are produced as required by the end user by a needs-based metering of the functional platform formulations.

In all of the above, there is a documentation of specifying and formulating the standardized platform formulations, in particular a documentation of the determined characteristics of the platform recipes and the use of liquid raw materials (slurries) and liquid semi-finished products / modular building paints required for the preparation of platform recipes due to platform recipes

Rather than relying on individual formulations, the development of product families is based on platform recipes.

Throughout the platform formulation, harmonization of the individual raw materials required for the production of building colors can take place. In this way, the number of raw materials to be used overall can be significantly reduced.

Instead of individual formulations preferably raw material semi-finished products are developed in the form of platform formulations.

The platform formulations represent a combination of raw materials in the sense of a greatest common multiple in order to use the respective platform formulation in a variety of ready-made formulations and / or final recipes.

For processing into a slurry, the required fillers in general and preferably semifinished products, in particular at the beginning of the production process, are converted into a liquid phase, ie dispersed.

The dispersion takes place so that only the platform recipes to be combined with one another have to be mixed together in the remaining process steps in the form of slurries.

An additional further dispersion can be omitted.

Semi-finished products in the form of binders are mixed with additives, preferably wetting agents, defoamers or preservatives.

Filler semi-finished products are z. As titanium dioxide, calcium carbonate, talc. The filler products are mixed with additives in the required quality and quantity.

Optimization of the water balance of filler semi-finished products

The use of semi-finished slurries, preferably in liquid form, means that many times more water is introduced into the production process than would be required in the respective finished product.

To regulate the water balance, the fillers and / or platform formulations in slurries are preferably combined with regard to the morphology and the particle size of the end product in such a way that a high packing density can be achieved.

Due to the high packing density, the water content in the slurry can be reduced to an optimum level.

process parameters

For the individual raw materials and intermediates, the process parameters are determined. These include viscosity, temperature, speed of the dispersing unit, dispersion time and other parameters which are familiar to the person skilled in the art. To maintain and optimize the process parameters, a general processing sequence of the raw materials and intermediates is preferably maintained.

Dispersion only at the beginning of the process

The fillers or raw materials are dispersed at the beginning of the process. This is preferably done only once. The fillers are subsequently further processed in liquid form as slurries or stored in process tanks until further use.

Dispersants are preferably added which sludge the solid particles in the liquid and hold them in suspension. In the slurried state, the solid particles are suspended in the liquid phase.

Dispersants are additives that allow or stabilize the dispersing, ie the optimal mixing of at least two, not really immiscible phases (substances).

With the help of the combination of solid and liquid raw materials into a slurry, the number of components and processing stages to be processed is considerably reduced in the production of building colors.

With the help of slurries, end products can be modularly built in building paints. The color modules can be mixed together in the form of platform formulations as needed.

The dispersion preferably of the raw materials takes place during the process of manufacturing the building color only once at the beginning of the manufacturing process.

Until further processing of the slurry, the blended raw materials are stored in tanks. The slurries are only mixed in the further production process.

Repeated dispersion is not required.

The dispersion and processing of the raw materials into a slurry takes place immediately after the suction of the respective substances from the silo wagon.

The need for an additional cost-intensive silo and powder handling technology is thus eliminated.

microbiology

The process steps which are required in the production of building paint for the production of a usable (tradable) slurry are described in more detail below.

In the following, the slurry is preferably designed as a platform formulation or as a finished product or as a semi-finished product in color production.

There is a seeding of the slurry to prevent bacterial contamination during storage, preferably in the process tank or transport in tanks.

Within the slurry, the state of bacteria formation is permanently measured (screened) using the already known analysis method.

As a result, the quantity and quality of bacterial activity in the slurry are continuously determined within a few minutes. In contrast to the sample preparation, the measurement takes only a few minutes.

Depending on the measurement result, a preservative and / or antibacterial agent is preferably added to the slurry, which is adapted in quality and quantity to the quantity and the quality of the bacterial attack of the slurry.

In this way, a gentle and needs-based addition of preservatives is possible.

All raw materials of the platform formulation which are incorporated in the color production and preferably present in the form of slurries, preferably comprising binders, pigments, solvents and additives, can be effectively protected in this way against microbial contamination.

In addition, it is possible to save preservatives.

An overdose of preservatives can be effectively avoided.

Resistances of the slurry against bacteria formation can be effectively restricted.

The restrictive use of preservatives requires a close microbiological monitoring of the slurries and the semi-finished product having platform formulations.

The measuring methods used so far, in particular dip slides and agar nutrient media, require long test times, in particular 48 to 72 hours.

Experimental and test series are carried out to define the platform formulation required for a production that is largely impermeable to germs.

The underlying production methods are preferably simulated on a miniature system and the required preservative addition determined by means of the already known analysis method.

logistics

Since, as explained further dispersion is no longer necessary, but the slurries or intermediates are subjected to only a simple mixing process, a continuous production or production on demand, even at decentralized locations is possible.

Storable slurries can be transported over long distances in tank trucks and enable storage and further processing decentralized places, without that there must be a full-fledged paint factory. This means that cost-effective capacities for the production of paints can also be built up in remote locations within a few weeks.

The above applies not only to slurries, but also to the processed modules of the platform recipe for the purpose of customization being made at a location other than the place of precursor to customization.

An advantageous embodiment of the modular platform formulation and the system results from the description of the following figures. Hereby show:

1 a situation in which only one process tank is present in the plant and

2 a situation in which two process tanks are provided and

1 shows a plant with only one process tank 1 . 10 , where the dispersion is assumed to have already taken place:
The slurry 2 can the process tank 1 . 10 fill in different volumes.

Is the process tank 1 . 10 about completely with the slurry 2 filled, so can in this process tank 1 . 10 a further processing of the slurries 2 not done, as far as this further processing would consist in the addition and mixing of other raw materials. In this case, the slurry would 2 on the one hand in its capacity as a standardized, universally applicable, liquid semifinished product, be a salable end product and accordingly in transport or sales containers 4 be bottled. On the other hand, in this case, the slurry would 2 preferably by means of a pipe connection 5 completely or partially to a storage tank located in the main works 6 can be forwarded.

With only partial forwarding of the slurries 2 to the storage tank 6 now arises free volume for the purpose of further processing of the slurries 2 in the process tank 1 as described above by adding binders 7 and additives and by mixing the slurries 2 with the same occurs.

Will, however, the slurry 2 partially or completely from the process tank 1 in the storage tank 6 forwarded, then a further processing of the slurries 2 at a subsequent time. For a later further processing of the slurry 2 back into the process tank 1 . 10 pumped back. The for the subsequent further processing of the slurries 2 respectively required raw materials 3 , such as B. binders 7 Be directly into the process tank 1 . 10 introduced, in which the subsequent processing takes place.

In 1 is an agitation device 20 represented, which is a functional and / or constructive part of the storage tank 6 is.

It is possible the slurry 2 from the process tank 1 . 10 to fill it for further transport and the slurry 2 then at a location 8th store outside of the main plant and by mixing with binders 7 and additives continue to process there. For this purpose, there is no need to continue the dispersion. The mixture may be by a previously described agitation device 9 respectively.

The above procedure of further processing in the process tank 1 . 10 Of course, this is even more possible if it is not complete with the slurry right from the start 2 is filled so that there is sufficient volume of other components.

The system also has a buffer tank ( 18 ) for further raw materials in small quantities z. As cellulose and / or for other, especially powdered ingredients. These raw materials and components are first transferred from a silo tanker (not shown) to the buffer tank ( 18 ). The buffer tank ( 18 ) is used to compensate fluctuating flow rates during discharge. The raw materials are added to the process tank ( 1 . 10 ) either directly from the silo tank or via the buffer tank ( 18 ).

Depending on the recipe, at least one process tank ( 1 . 10 ) from a container ( 19 ) Other recipe ingredients, such. As thickener, titanium dioxide, kaolin or other powdered ingredients supplied.

2 shows a situation where two process tanks 1 . 10 , available:
The two process tanks 1 . 10 can each perform the same tasks functionally identical. Preferably, it is functional, but in particular also spatially separated, between the two process tanks 1 . 10 a dispersing device 11 provided in a dispersing chamber. Again, the dispersing device 11 the rotor / stator device, as described above. Another type of dispersing device 11 is of course also possible. The word "between" is not to be understood in the sense of a spatial arrangement, but rather describes the operative connection of the dispersing device 11 with the two process tanks 1 . 10 ,

For this purpose, the dispersing device 11 with wires 12 with the process tanks 1 . 10 connected. It can, as previously described, a cycle-like, continuous dispersion take place. The circulatory dispersion may be on one (not shown) or both process tanks 1 . 10 be related. This means that the dispersing device 11 can be switched so that they are either only with a process tank (not shown) 1 . 10 or with both process tanks 1 . 10 communicated. This results, as also described above, the slurry 2 from a dry powder or from a dry powder mixture and a liquid 13 , optionally other ingredients (not shown) included.

Between the two process tanks 1 . 10 is a lead 14 , In particular pipe connection arranged through which the slurry 2 depending on the needs of a process tank 1 . 10 to the other process tank 10 . 1 or vice versa directed, preferably can be pumped.

The arrangement of two process tanks 1 . 10 allows a particularly flexible design of the modular manufacturing process.

Be about both process tanks 1 . 10 about halfway with the slurry 2 filled, it is possible by adding more process materials 7 in both process tanks 1 . 10 to carry out either the same or different further processing or finishing, depending on which type of building color is to be produced. With these, the slurry 2 added substances 7 it may be, for example, a binder dispersion, additives, preservatives, thickener systems for adjusting the rheology, defoamers, etc. Since a dispersion has already taken place, it is no longer necessary for this further processing. A mixing process by means of an agitation device 9 is sufficient for this. After production of a composite of this type further intermediate or end product emptying takes place in transport or sales containers 4 ,

But it is also possible that only one of the two process tanks 1 . 10 with the dispersed slurry 2 is filled. In this case, part of the slurries 2 from this process tank 1 . 10 the other process tank 10 . 1 by means of one between the two process tanks 1 . 10 arranged line 14 , z. B. pipe connection, are supplied. In this case, in the process tank 1 . 10 which the slurry 2 has been supplied, a further processing of the same to a next finishing or finishing stage after the aforementioned explanations are performed.

One in which the slurry 2 dispensing process tank 1 . 10 remaining residue of slurry 2 , regardless of the volume, can either be emptied as a semifinished product for the purpose of sale. In this case, the semi-finished product is practically the salable end product 16 , It is also possible that the rest of the slurries 2 is transferred to another destination tank, z. B. in a storage tank 6 at the main location of the main color production plant (not shown), by means of which subsequent processing takes place at a later time. The forwarding to the storage tank 6 is preferably via a line, in particular pipe connection (not shown). As a target tank but also comes a storage tank 6 outside the main plant 8th into consideration; In this case, the dispensing process tank 1 be dumped and the slurry 2 in a transport container 4 be bottled.

As far as above from the further processing of slurries 2 in the one process tank 1 . 10 or in both process tanks 10 . 1 It should also be noted here that further processing or finishing is a largely standardized semi-finished product in the form of slurries 2 underlying and in the last process step by admixing quality-determining raw materials 3 and additives the desired end product is achieved.

The at least one process tank 1 . 10 can be designed such that a removal of the slurries 2 and / or the further processing product for the purpose of analysis for the presence of microbial contamination is possible. Further details are so far in connection with the storage tank 6 shown, the same for the process tank 1 . 10 be valid.

Both process tanks 1 . 10 can be considered constructive as two separate, independent process tanks 1 . 10 be executed. They are structurally separated from each other in this case. But they can also be arranged in a parent container system (not shown) and thereby separated from each other by a partition wall. There is also the possibility that both process tanks 1 . 10 are functionally and structurally designed as a unit (not shown) and the dispersion for the preparation of the slurries 2 by means of a dispersing device arranged separately therefrom 11 he follows. In this latter case, the dispersing process is preferably switched on in phases. Both process tanks 1 . 10 Thus, they can be used independently of each other in all situations described above.

After the process tank system has been explained in summary, it will be discussed below on the other parts of the plant and their function in the context of the manufacturing process for building colors.

As shown, the process tank 1 . 10 either directly or indirectly, e.g. B. via a powder container 15 , Dry powder for the purpose processing into a slurry 2 fed. This dry powder 13 may contain a raw material or comprise a raw material mixture.

Depending on the recipe, the least one process tank 1 . 10 in addition to the withdrawn, mentioned raw material or in addition to the raw material mixture, or was taken from the tank car, further formulation ingredients 7 , such as As thickener or titanium dioxide or kaolin or other powdered ingredients supplied. This can be done by about the cellulose or other powdered components discharged from one or more other containers, in particular pumped or sucked off and in the at least one process tank 1 . 10 be transferred.

2 further shows a plant and a process situation in which one or both process tanks 1 . 10 the relevant slurry 2 directly or indirectly to at least one storage tank 6 was forwarded.

Immediately or indirectly in this context means that the storage tank 6 either in the main work of the paint manufacturing process (not shown) and / or in a location outside the main plant 8th is available. The further processing of the slurries described below 2 in a storage tank 6 is basically the same, regardless of whether the further processing in the main plant or in a location 8th takes place outside the main plant.

In this one or more storage tank 6 becomes the slurry 2 stored and serves the flexible further processing due to the illustrated modular platform formulation.

Also outside the location of the main plant 8th the paint manufacturer serves the storage tank 6 the storage of the slurries 2 , For further processing outside the location of the main plant 8th In particular, a separate mixing tank is used, in which all required modules are merged. The mixing of the substances 3 . 7 takes place by means of a stirrer. A repeated dispersion at a location outside the main plant 8th the paint manufacturer is no longer required.

This storage tank 6 has a stirring device, by means of which the slurry 2 in the storage tank 6 be stirred continuously or periodically.

The stirring device may be on the outside of the storage tank 6 be arranged and protrude by means of suitable construction with the agitator in this.

This storage tank 6 also has a device, for. As a valve, for removal, so that its contents can be fed to a real-time analysis on the microbacterial consistency.

The facility also includes facilities for conducting an analysis 17 to determine the microbiological state of the slurries 2 , especially those slurries 2 in the at least one storage tank 6 outsourced. The analysis device 17 performs a so-called hygiene analysis after appropriate sample preparation. With the analysis device 17 is analyzed, if and to what extent a contamination of the slurries 2 given is;
If yes, the total germ count is preferably determined and displayed. The analysis device 17 is designed not only to detect and indicate the microbial contamination as such, but also to carry out an activity analysis of the germs.

Based on the determined results and a method for the interpretation of the measurement results, it is possible to preserve the recipe individually. This needs-based supply of preservatives is harmless to human health and the environment. The real-time analysis enables a fast reaction and prevents further bacterial contamination through the early addition of selective biocides.

After this summary, the individual process steps, components and devices will be discussed.

LIST OF REFERENCE NUMBERS

1

process tank

2

slurry

3

Raw materials (binders, additives, etc.)

4

Transport and sales container

5

pipe connection

6

storage tank

7

Other raw materials (binders, additives, etc.)

8th

Location outside the main plant

9

agitation device

10

process tank

11

disperser

12

management

13

Dry powder and liquid

14

management

15

powder container

16

end product

17

analyzer

18

buffer tank

19

Container for thickener

20

agitation device

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 0682094 [0092]

Claims (15)

Standardized liquid semifinished product for the production of architectural paints, characterized in that the semi-finished products can be used both as a salable end product or as a basis for further processing and / or finishing. Semi-finished product according to claim 1, characterized in that this is based on slurries ( 2 ) is made. Semi-finished product according to claim 1 or 2, characterized in that it can be produced by a process comprising the steps of producing a slurries ( 2 ) from raw materials ( 3 . 7 ) and / or from a premix of raw materials and water by means of dispersing, wherein the slurry ( 2 ) in at least one process tank ( 1 . 10 ) is prepared with dispersion. Semi-finished product according to claim 3, characterized in that this further processed by adding binder and / or additive is finished. Semi-finished product according to claim 3 or 4, characterized in that the customization of the last produced product ( 16 ) takes place in the last possible method step. Semi-finished product according to claim 1 or 2, characterized in that it is produced by a process according to one or more of claims 3 to 5, comprising the steps that the slurry ( 2 ) in the at least one process tank ( 1 . 10 ) in turn undergoes one or more further processing or refining step (s). Semifinished product according to one or more of claims 2 to 6, characterized in that the slurry ( 2 ) after its production or after its further processing and / or finishing to a semi-finished product in the at least one process tank ( 1 . 10 ) to at least one storage tank ( 6 ) in the major paint factory and / or in a foreign site ( 8th ) and the slurry ( 2 ) or the semifinished product is subjected to further processing and / or finishing at a later time. Semi-finished product according to one or more of claims 2 to 7, characterized in that the slurry ( 2 ) in the at least one process tank ( 1 . 10 ) and / or in the slurry and semi-finished product storage tanks ( 6 ) a microbiological analysis ( 17 ) and treatment in real time, the treatment being of the same scope and extent as the result of the analysis ( 17 ) is adjusted. Semifinished product according to one or more of Claims 2 to 8, characterized in that it contains the raw materials ( 3 ; 7 ) for the slurry ( 2 ) Titanium dioxide, filler, additive. Semi-finished product according to one or more of claims 2 to 9, characterized in that the in the process tank ( 1 . 10 ) or further processed and / or refined slurry ( 2 ) with other raw materials ( 3 . 7 ) is mixed. Semi-finished product according to one or more of claims 2 to 10, characterized in that the slurry ( 2 ) as part of the customization a binder dispersion and / or an additive and / or preservative ( 3 . 7 ) are mixed. Semi-finished product according to one or more of claims 2 to 11, characterized in that the rheology of the mixture is adjusted by adding thickener. Semi-finished product according to one or more of claims 2 to 12, characterized in that the mixture in the case of further processing and / or finishing thickener and / or defoamer and / or other substances ( 3 . 7 ) are added. Semifinished product according to one or more of Claims 2 to 13, characterized in that the customization is carried out locally at another place ( 8th ), as the place of manufacture of the precursors for customization. Building color, characterized in that it can be produced by a process for the production of semifinished product according to one or more of claims 1 to 14, wherein the customization of the last produced intermediate ( 16 ) takes place in the last possible method step.

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