Scope

Paint & Varnish

Process-integrated cleaning of ink deposits with the stationary comprex® technology

In 2020, the EU guidelines for the use of biocides and preservatives were tightened. The companies were given two years to change their production and adapt to the new regulations. Increased requirements are thus placed on raw material quality and operational hygiene during production.

The aim is to keep production plants for emulsion paints hygienically clean. Contamination with product residues after pigging and in non-piggable areas is a problem for many operations. Rinsing with water is unsuitable for the complete removal of residues. In addition, there is high water consumption and correspondingly large amounts of wastewater.

The product residues harden into stubborn deposits and thus require even more cleaning effort. The result: more plant downtime!

Continuous cleaning of the product lines creates the basis for lasting cleanliness. Ideally, process-integrated and automated cleaning will be established as a fixed production step in your plant so that you can clean your equipment in sections at any time.

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2018
A major manufacturer of emulsion paints discovers comprex®. Several tests follow at the customer's site and in our technical center. By applying paint to pig garages, pig switches and pumps, it is possible to see how effective comprex® is on critical components.

This is followed by practical trials with the comprex® technique in different mills on various tasks. The effectiveness of the pulse flushing method is tested on risers and branched pipelines, as well as checked for the effect at different section lengths and direction changes.

First test cleanings on pipelines for dispersion paints

Focus: Cleaning during product changes

First tests with pig traps

Pump cleaning

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Cleaning tests with rotary lobe pump in the test plant

Placement of varnishes for test cleaning

Transparent end plate for visual assessment

2019
After comprex® has been put through its paces, the manufacturer decides to equip a first plant with comprex® technology in cooperation with the plant manufacturer OAS AG from Bremen.

Equipping a production site for emulsion paints with stationary comprex® controller

Communication with PROFINET & remote maintenance

fully automatic cleaning programs

6 pig lines with over 70 sections

Integration in production plant

2020
Two years later follows the re-commissioning. For the new construction of a production line, the integration of 6 stationary comprex® units follows. The manufacturer uses a combination of ECO and intensive cleaning.

Planning with plant manufacturer for complete equipment of a new production plant

Different versions in terms of size, control, positioning

Cleaning programs on demand

Automated and process-integrated cleaning

Installation of six SCU

Mobile cleaning for Meffert AG

2019-2020

At the same time, Meffert AG Farbwerke, one of the leading manufacturers of paints and coatings, became aware of comprex®.

The challenge: preservative-free production. Meffert is initially testing the impulse flushing process at a plant in Bad Kreuznach for cleaning filling lines.

This is followed by tests with pumps in the Landau pilot plant. Meffert acquires its first own mobile comprex® unit (MCU-300) to subject product lines, pig lines, pumps and distribution trees to targeted regular cleaning processes. Individual cleaning programs are stored for each section.

In the meantime, the comprex® technology is in use in several plants.

"The MCU-300 from Hammann represents an important component of our innovative industrial hygiene concept. The system is used at Meffert AG both for flushing pipelines and for cleaning stand-alone systems. The cooperation with the colleagues from Hammann has worked very well since the beginning of the project.

Project planning and commissioning were transparent and professional. All inquiries are processed promptly, and ideas and optimization requests are discussed openly with our technical department even months after commissioning.
The MCU-300 is intuitive for our employees to operate, can be used almost anywhere due to its dimensions, and works very reliably."

Cooperation with BCD Chemie – the Sinner’s Circle in the Optimum

2021-2022

In practice, mechanical or chemical approaches are used to clean surfaces. comprex® effectively cleans even in critical places such as pig garages, pumps, filters, risers and branched pipelines. This keeps new plants clean and prevents contamination after product changes.
Aged paint deposits require more intensive treatment. Over a period of six months, we worked with our cooperation partner BCD Chemie to develop an innovative, process-optimized solution for cleaning pipes that are sometimes covered with decades-old deposits and layers of paint. The multiple combined use of comprex® in conjunction with the cleaner WBC 333 makes these old components usable again.

The synergistic effect of mechanical and chemical cleaning can be used to efficiently remove aged paint deposits from stainless steel lines in the shortest possible time.

For decades, BCD Chemie has focused on marketing industrial and specialty chemicals and is one of the leading suppliers in this segment.

Take Away Message

The combination of chemical soaking and mechanical mobilization and removal is the most time-efficient way to clean OLD paint layers from steel surfaces

strong mechanics + strong chemistry creates a previously unmatched cleaning performance

The cleaning target is reached at room/hall/outdoor temperature. Temperature control is not necessary.

Time separation between chemistry and comprex® is possible

The SCU series

Our novel stationary COMPREX® modules are suitable for regular cleaning of, for example, product lines, pig lines and other pipelines in your production. Regular cleaning reliably removes residues from the pipelines before deposits can form.

For more information, please refer to this product sheet:

FARBE UND LACK: New impetus for plant cleaning

The comprex® process ensures hygienically flawless production facilities even with preservative-free production of water-based coating materials. As a process-integrated stationary version, they operate in an automated and resource-saving manner.

EUROPEAN COATINGS JOURNAL: Process Integrated Plant Cleaning

Automated cleaning, reduced water consumption, no issues with geometries. By Sebastian Immel and Norbert Klein, Hammann & Hammann Engineering, Jan Walther, sycotech.

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