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

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

Country: India

Solutions: Integrated MES and DCS



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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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Originally published in ABB Contact magazine
Operations Management Software for specialty chemicals
Process control and automation for specialty chemicals
Batch automation software
ABB solutions for paints, coatings and resins manufacturing
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