Process improvement in industrial paint manufacturing: a case study on Monocoat production

Abstract

This thesis investigates process improvements in the Monocoat production at the PPG Industries Quattordio plant, focusing on efficiency, automation, and workflow optimization. Monocoat is a specialized single-layer paint designed for industrial applications, offering advantages in production speed and consistency. The study provides a detailed analysis of the Monocoat production process, cov- ering key stages such as dispersion, grinding, and final completion. It identifies inefficiencies in material handling, automation, and process flow, proposing targeted optimizations. A major aspect of this research is the integration of the Pre-grinding Mill, which enhances the pre-dispersion and grinding phases, significantly reducing processing times while ensuring product quality. In addition, the study evaluates the automation of raw material handling, op- timizing dosing systems and material transfer to reduce manual intervention and improve process reliability. Special attention is given to the selection and installa- tion of new pumps, ensuring optimal flow rates and pressure management across different stages. The implementation of an automated process sequence further streamlines operations, improving consistency and reducing operator workload. Economic feasibility is also assessed, confirming that the proposed improvements offer a payback period of less than 2.5 years, demonstrating their financial viability. Overall, this thesis demonstrates that through targeted process improvements and automation, the Monocoat production line can achieve greater productivity, operational efficiency, and cost-effectiveness, reinforcing its competitiveness within the industrial coatings sector.