One of the world's largest DCS and MES projects for integrated paint manufacturing process

Integrated plant automation system for Asian Paints increases reliability, ultimately resulting in savings, better material usage and reduced losses

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Asia’s third largest paint company, Asian Paints set up a greenfield plant for decorative paints with production capacity of 225,000 kilo liter per annum (kl/a) water based paint, 70,000 kl/a of solvent based paint and 5,000 kl/a of machine colorants at Khandala

End-to-end solution

After rigorous market research, Asian Paints selected ABB for the design, engineering, project management, installation, commissioning and service of the integrated MES (Manufacturing Execution Systems) and DCS (Distributed Control System) solutions for its new plant. Having around 42,000 I/Os, it is an end-to-end solution that controls and integrates plant processes from raw material receipt, storage and transportation to paint manufacture and packing.

Main facts

Industry: Specialty chemicals

Company: Asian Paints


Solutions: Integrated MES and DCS

Greater flexibility and agility

Manufacturing Execution System (MES) for paint processes enables higher plant efficiency and productivity, as well as greater flexibility and agility throughout the production processes of polymer, resin, water and solvent based paints. The system, with its increased reliability, ultimately results in savings, better material usage and reduced losses that may arise out of production breakdown. ABB System 800xA Smart client enables the management to have the key production data and reports just at a click of a button.

From concept to commissioning

ABB solutions not only reduced manpower required to operate the plant and production cycle time, but also significantly cut the downtime.

Involving a high degree of customer interfacing, ABB was the single point for turnkey automation (DCS and MES) of the plant, from concept to commissioning.

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