Installation of 10 Russell Eco Filters enables Visen to double its production capacity

Founded in 1985, Visen is widely recognised as one of the top producers of water-based emulsion. With its products being sold to numerous long-established paint manufacturers across the world and with manufacturing facilities in several locations across India, Visen produces more than 120,000t of latex emulsion every year.
In 2011, to meet increased customer demand, Visen invested in new manufacturing facilities. Built in India, it was anticipated that the new plant would virtually double its production capacity to 220,000t/yr. To ensure the plant was equipped with the latest technologies, the company undertook a review of all its existing processes.
As a result of the review, it was identified that the existing quality control procedure in place for check-screening the latex emulsion prior to packing needed to be improved. The current procedure was carried out using a simple filter cloth system, which would catch any contamination in the paint as it is fed into the packing containers.
Although fit for purpose, improvements were identified, which, if implemented, would provide significant increases in production efficiency. Being an open system meant the cloths and paint were exposed to atmospheric influences, which increased the possibility of skins forming in the latex emulsion. This could cause the filters to block or end up contaminating the final product. As a result machine operators were required to continually watch the line, which increased their exposure to the latex emulsion. In addition, the filter cloths needed to be changed between each new batch and with several filling lines in operation, up to 10 filter cloths could be used in any one day. As the cloths were not reusable, the company also incurred high disposal and replacement costs.

ONSITE TRIAL
Whilst it recognised its importance, it also acknowledged the inefficiencies of this existing system. In search of a new filtration system, Visen attended the Middle East Coatings Show in Dubai to talk to potential suppliers. Intrigued by the filtration system displayed on the Russell Finex stand, Visen approached stand representatives to learn more about the machine.
With an in-depth consultation provided, an onsite trial was arranged for the Self-Cleaning Russell Eco Filter.
With the filter installed into its own production line, the trial enabled Visen to undertake personal monitoring of the machine’s effectiveness. "It was important for us to be able to trial the filter at our plant prior to purchase, not only to ensure that product quality would not be compromised but also to ensure operators would be safeguarded from the potentially harmful fumes,” states Mr V M Salunkhe, Manufacturing Manager at Visen’s plant in India.
Following the success of the trials, Visen recognised the potential savings that would be gained prompting it to purchase 10 Self-Cleaning Russell Eco Filters.

SUBSTANTIAL COST SAVINGS
The installation of the filters has enabled Visen to eliminate the problems associated with the previous system. With its reusable filter element, the Self-Cleaning Russell Eco Filters have minimised production downtime as stoppages to change filter cloths are no longer required. Substantial cost savings have also been gained as the removable element can be easily cleaned and used repeatedly, removing the high disposal and replacement costs, which Visen experienced with the filter cloth system.
A key requirement was for the new system to operate without constant supervision. Being a fully enclosed system, the product is unaffected by atmospheric elements and, therefore, minimises the possibility of skins forming in the latex emulsion, which would subsequently form blockages.
In addition, with the installation of the Russell Filter Management System, which is designed to continuously monitor the filtration process, the filter is able to run efficiently without operator involvement. This not only safeguards operators from excessive exposure to the latex emulsion but also releases the operators to perform other tasks around the factory. Salunkhe states: "Compared to our previous manual filtration system, the enclosed Eco Filters have allowed us to achieve good house keeping and reduce labour costs”.
The installation of the Russell Eco Filters has improved Visen’s manufacturing efficiencies, whilst also enhancing its already meticulous quality control procedures.
For more than 75 years Russell Finex has manufactured and supplied filters, sieves and separators to improve product quality, enhance productivity, safeguard worker health and ensure liquids and powders are contamination-free.
Throughout the world, Russell Finex serves a variety of industries with applications including food, pharmaceuticals, chemicals, adhesives, plastisols, paint, coatings, metal powders and ceramics.