Maximizing Production Efficiency and Safety in High-Volume Flammable Coating Filling

 

Customer Production Process

In the global chemical and coatings sector, manufacturers face the constant challenge of optimizing high-speed production while adhering to some of the strictest safety and environmental regulations in modern manufacturing. Whether handling architectural paints, heavy-duty industrial finishes, or specialized automotive refinish coatings, they require reliable, explosion-proof automation capable of adapting to diverse product viscosities and fast-paced market demands. PACK’R has long been a trusted engineering partner for global chemical leaders in this space, developing cutting-edge net-weight filling and capping solutions that safeguard operators, protect product integrity, and eliminate costly down-time.

To overcome these challenges, PACK’R Team deployed an automated, hazardous-area rated monobloc system engineered for high throughput, exceptional filling accuracy, and rapid product changeovers.

 

Challenges

Packaging industrial solvent-based paints involves navigating critical safety and production constraints:

  • Hazardous Environment EXPROOF:

The presence of flammable solvent fumes required an engineered solution compliant with explosive-atmosphere safety standards (Explosion Proof Class I, Division 1 & 2 environment).

  • Product Variability & Waste Reduction:

Handling premium coatings meant minimizing product loss at the end of production runs.

  • Frequent Format Changes:

The facility needed to run 4 distinct container sizes ranging from 1-quart cans to 5-liter containers and three separate plastic cap configurations without causing substantial downtime during shifts.

  • Strict Accuracy Need:

Minimizing overfilling (product giveaway) while guaranteeing regulatory net-weight compliance was essential to protecting production margins.

 

PACK’R Filling Solution

REVO-S – High-Speed Filler Capper for paint and coatings industry

We designed and integrated a Rotary Filler/Capper REVO-S with 12 net-weight filling stations and 4 heads press-on capping system.

To guarantee maximum precision and strict regulatory compliance, the system utilizes advanced Net-Weight technology. By weighing each container individually in real-time during the filling cycle, the machine effectively eliminates product giveaway and prevents costly waste from overfilling.

The REVO-S filler/capper is a Rotary Filler/Capper with a continuous motion designed to fill fully automatically and cap every container at high speeds.

PACK’R Rotary machines are the best solutions when needing high accuracy and high production rates.

High-Volume Flammable Coating FillingCapping system for cans

 

Technologies & Key Features

  • Net-Weight Filling & Pressurized Tank

Instead of using a standard gravity tank, PACK’R machine was designed with a pressurized tank system. Pushing product via controlled pressure allows the system to seamlessly adapt to a wide range of liquid viscosities without requiring mechanical modifications. Each station features a dual-flow valve (large and fine flow) ensuring a filling accuracy of 0.25%.

  • EXPROOF Class I, Division 1

To ensure safe runs within a zone with flammable products, the REVO-S was fully engineered to meet Class I, Div 1 and Div 2 standards. The machine also integrates a nitrogen purging systems to flush containers before and after filling, protecting product shelf life.

  • Easy Changeovers with PACK’R "Click & Play"

To optimize line efficiency, the system utilizes color-coded formats that allow line operators to execute complete format change quickly and without using tools. Motorized carrousels and cap magazines automatically adjust their heights based on pre-recorded recipes selected on the system’s HMI.

  • Fully Automated "Clean & Play" CIP System

Cleaning a paint line can lead to long downtime. The patented Clean & Play system provides a fully automated Clean-in-Place (CIP) cycle. Nozzles automatically plug into a closed CIP cup, wash with hot solvent or water. This sequence completely changes the standard process leaving less than 15 liters of cleaning wastes and reducing total batch cleaning time down to just 10 minutes.

 

Results

The machine achieved high filling rates for all containers:

  • 1-Quart Containers: 100 cans per minute (cpm)
  • 1-Gallon & 2.5-Liter Containers: 65 cans per minute (cpm)
  • 5-Liter Containers: 45 cans per minute (cpm)

This project demonstrates PACK’R capability to deliver durable, high-speed automated packaging machinery that follows the most complex requirements while safeguarding line operators and driving long-term corporate profitability.

 

Innovative PACK'R Technologies for the Paint Industry

Explore how PACK'R addresses the specific requirements of paint applications with advanced pail filling technologies. Featuring the REVO-B automatic filling solution, this video highlights key innovations designed to deliver high filling accuracy, production efficiency, product savings, and simplified operations through intelligent filling, capping, tooling, and cleaning systems.

 

Looking for a Paint Filling Machine?

Contact PACK’R to design an automatic filling and packaging solution tailored to your production needs.