Mini-MoFa - The world‘s most compact paint factory on 30 m² By Ralf Hohmann

1. Welcome
Speaker:
Ralf Hohmann
Divisional Production Manager
Hemmelrath Lackfabrik GmbH, Klingenberg am Main

2. The Modular World
„Mini-MoFa“
The world‘s most compact
paint factory
on 30 m²

3. Topics
1. „The Modular Paint Factory (MoFa)“ -
Philosophy
2. „The Modular Paint Factory“ -
Appropriate scale for each individual application
3. „The Mini-MoFa“ -
The world‘s most compact paint factory
4. „The MoFa Concept“ -
General

4. 1. „The Modular Paint Factory“ -
Philosophy
Status Quo: Dissolver Production
• Manual – semi-automatic production process
• Maximum batch sizes up to 7 tons
• Time consuming dosage of solids from silos
• Indeterminate homogenization and wetting
• Increased aeration
• Small production window when processing various viscosities
• Standardized milling processes with a max. output 1 ton/hour
• Out-dated stirrer technology

5. 1. „The Modular Paint Factory“ -
Philosophy
Perspective: Modular Production
• Fully automated production processes
• Variable production quantities up to > 50 tons
• Online dosage of solids from silo trucks
• Enforced dispersion and wetting
• Mixing without aeration
• Large production window when processing various viscosities
• Innovative process milling technology with an output of > 10
tons/hour
• Jetstream mixing technology

6. 1. „The Modular Paint Factory“ -
Philosophy
Figures:
• Investment costs - 50 %
• Required space - 50 %
• Labor costs - 50 %
• Quality + 100 %
• Energy costs - 70 %

7. 1. „The Modular Paint Factory“ -
Philosophy

8. 2. „The Modular Paint Factory“ -
Suitable scale for each individual application
1. „Micro-MoFa“
Production batch: 2 – 300 litres
2. „Mini-MoFa“
Production batch: 300 – 5,000 litres
3. „MoFa“
Production batch: 5,000 litres - unlimited

9. 3. The „Mini-MoFa“
The world‘s most compact paint factory
Model Types 1 – 5 as well as HV (High-Viscosity) Variants
Advanced innovation due to:
• Integrated Jetstream technology
• Powder dosage with reusable bulk material containers without
dust formation
• Dispersion unit Conti-TDS can be switched on/off
• Dosage of small amounts below the surface
• Trend-setting SPS control via touch screen monitor
• Integrated cleaning module
• Maintenance concept of the future

10. 3. The „Mini-MoFa“
The world‘s most compact paint factory
Strategic competitive advantages due to:
• The use as a development module for new formulation options
• The use as a production line
• The use as a scale-up monitor for large batch production in
the MoFa
• The use as an indicator to determine production costs

11. 3. The „Mini-MoFa“
The world‘s most compact paint factory
Advantages vs. Dissolver Production
• Shorter production times
• Lower energy costs
• Lower labor costs
• Higher capacity
• Flexible batch sizes
• Constant production parameters
• Lower testing costs with increased batch capacity
• Change of product as desired (black – white)

12. 3. The „Mini-MoFa“
The world‘s most compact paint factory
Advantages vs. Dissolver Production
• Reduction of additives in the formulation due to increased
effectiveness
• Better dispersion with Conti-TDS
• Aeration avoided during production process
• Reduction of odor emission
• Increased hygiene at work and cleanliness

13. 3. The „Mini-MoFa“
The world‘s most compact paint factory
Detailed information:
• integrated Jetstream mixing
technology
Mixing without aeration
Shortest, homogeneous dispersion
Agitator speed infinitely adjustable
Applicable regardless of filling level
Cleaning module included for all
possible product sequences

14. 3. The „Mini-MoFa“
The world‘s most compact paint factory
Detailed information:
• powder dosage with bulk material containers
Residue-free emptying
No dust formation
Enforced wetting with
dispersion unit
Easy to clean

15. 3. The „Mini-MoFa“
The world‘s most compact paint factory
Detailed information:
• trend-setting SPS control via touch
screen monitor
Fully automated production
procedure
Innovative visualization
Continuous recording of process
data possible
Integrated maintenance concept
via SPS

16. 3. The „Mini-MoFa“
The world‘s most compact paint factory

17. 4. The „MoFa Concept“
General
The Three Phase Business Model
• Phase 1: Consulting / Feasability Analysis
• Phase 2: Mini-MoFa
Micro-MoFa Know-How Transfer
• Phase 3: Use of modular production
Know-How Transfer
technology

18. 4. The „MoFa Concept“
Phase 1
• Secrecy agreement & consultancy contract
• Form competence team
• Plan & carry out workshops
• Develop modular formulations
• Optimise quality (sinus → linear)
• Define savings potential
• Define feasibility study
• Make decision about further phases

19. 4. The „MoFa Concept“
Phase 2
• planning, construction & commissioning
• model variants
Mini-MoFa Micro-MoFa
• Versions 1 – 5 • Micro-MoFa 10
• HV (High-Viscosity) Variants • Micro-MoFa 20 Labour
• Micro-MoFa 50
• Micro-MoFa 100 Technical
• Micro-MoFa 300 Centre
• HV (High-Viscosity) Variants

20. 4. The „MoFa Concept“
Phase 3
Planning, construction and comissioning of a MoFa as
a large-scale, technical solution
Batch size > 5.000 litres

21. Thank you
for
your attention!