The continuous search for more effective and environmentally friendly products in the adhesive and sealant industry requires manufacturing equipment to evolve accordingly. The behaviour of high-viscosity fluids, such as non-Newtonian shear-thinning fluids (pseudoplastic and thixotropic) requires ad hoc laboratory assessment to identify the specific rheology.

New materials mean new process parameters, like maximum pressure applicable to the product, controlled temperature (cooling or heating in the specific time window) and precise control of additives like pigments and/or catalysts.

Despite having established a detailed database of material features over the years, this can only be the starting point in the design of new equipment. Not only the formulation, but also the geometry dictated by a smaller/larger batch will have an effect on the machine design.

Characterization of the fluid rheology during mixing (i.e. from powder to fluid), pumping and filling plus the associated thermal management are key features for the design engineer. The correct sizing of the equipment ensures reliability in high cadence production environment; however, this is not the only goal: energy efficiency (i.e. optimal use of resources) is a common target to minimize the carbon footprint and running cost.

Innovation and flexibility in bespoke equipment development

All this requires a machine designed around the specific product and at Turello we are proud to provide the customer with fully customized equipment.

In a fast paced-industry, time is of the essence and no one can afford to wait (or pay) a complete redesign of new equipment from scratch and does not want to run the risk of operating a unique machine with indefinite timing in case of spare parts requirements. The solution implemented by our engineering team is a modular approach, like the building blocks: basic elements that can be combined in different way leading to unique features. Recently implemented AI-based tools accelerate the identification of the basic layout in relation to type of product, batch volumes and rheological curve. Advance design like structural and hydraulic load are performed and verified by our engineers.

Our 40,000 kg of spare components in the vertical warehouse and highly qualified technicians enable us to support the operating equipment around the globe.

The request for bespoke equipment is not triggered only by new products: there are many cases where space constraints and growing production demand require changes to the manufacturing processes. Installations like the TPM and the associated line have been the “vertical” answer to the increasing production capacity within a confined footprint, maximizing the quantity of product produced per square metre occupied.

Quality, know-how and customer support throughout the machine lifecycle

Experience and specialized know-how are essential in the design and construction of bespoke equipment. The entire project requires attention to detail during each step, from preparing the initial proposal to the transport arrangements. Continuous training and development of the team is needed to produce outstanding machines. Internal and external coaching sessions followed by project-specific experience are the foundation for any new starter: sharing lessons learned and failure mode analysis are invaluable tools for everyone in the company. Partnership with colleges and universities is an opportunity to attract rising stars and establish an engineering legacy.

Robust quality protocols and procedures must be deployed through the factory: full compliance with the project specification requires detailed records of all the components used. The final test performed at customer acceptance stage is only the end of a disciplined journey: daily process audits are performed to ensure and maintain the required standards.

Every machine must pass a series of tests specifically designed to validate key functions during the operating cycle and potential malfunctions due to operator errors or component failure (i.e. hose burst, electrical fault and similar events).

Each machine will not process the same product for its entire life, so it is important to have the possibility to upgrade or revamp the equipment over time while limiting capital expenditure. A close collaboration with customers is essential and the involvement of our engineers in the entire production cycle from the beginning is the key to success.

Although “bespoke” might be associated with revolutionary design, Turello’s focus is on evolution: we want to build innovative equipment without compromising the reliability and robustness required by the industries we serve. Tailored machines are the result of a methodical approach combined with the ability to integrate existing, validated components with innovative solutions.

To discover how our solutions can support your manufacturing processes, we look forward to welcoming you at Stand 452 during Paint & Coatings Italy on October 28–29 at Allianz MiCo in Milan.

TPM – Turello Press Mixer

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