Paint Filling Line Through the Valve – Automation of Pigment Dosing in an ATEX Environment

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For our client, a major European paint manufacturer from the Czech Republic, we developed an automated line for dosing pigment into pre-filled aerosol cans containing solvent and propellant. The project was created in response to the need to eliminate manual pigment measuring and dosing – a time-consuming and error-prone process that had long dominated the industry.

Client: Major European paint manufacturer, Czech Republic
Project date: Q3, 2025

Project goal: Automation of pigment dosing through the valve, improvement of efficiency and repeatability, and ensuring valve cleanliness after filling.

The Challenge

In traditional paint production processes, the can is filled with pigment, a mixing ball is added, the valve is crimped, and propellant gas is injected. This is the most conventional method, typically used by manufacturers with their own gas infrastructure.

However, for smaller-scale producers or those operating in locations with environmental or administrative restrictions, the pre-filled can model is much more practical.

We are experienced in both approaches, and in this project the client was looking for a solution that would enable automatic pigment dosing directly through the valve, while maintaining full cleanliness of the process.

Existing market systems for valve-based paint dosing are precise but largely manual, requiring operators to measure and handle pigment for each cycle.

The goal was therefore to develop a fully automated line that eliminates manual intervention and ensures a clean valve after filling.

A dirty valve not only raises questions about process quality but can also clog the spray head and prevent proper dispensing of the paint.

Work progress

Our Solution

We designed a complete line operating at 20 cans per minute, with scalability up to 40 cans per minute.

The system was built around our unique Fill&Clean™ technology and Turn&Go™ stands, which allow:

changeover time reduced practically to zero for the same can diameter,
cleaning of inactive heads and dosing circuits while others remain in production,
immediate startup of a new production batch right after the previous one ends.

A key element of this project was our custom-designed dosing head with a dedicated pigment nozzle, optimized for paints of different colors and physical properties.

This component ensures precise, clean dosing without valve contamination – unlike many systems that use standard gassing nozzles for this purpose.

While gas can be safely dosed through a standard valve, paint requires a more delicate and controlled process to avoid splashing and impurities.

Operator Safety

The entire line was designed for operation in an ATEX environment, with full safety enclosure and operator protection.
Importantly, the cleaning of dosing circuits also takes place inside the safety enclosure, in parallel with ongoing production.
The operator can safely connect and collect flushing liquids without stopping the machine and without exposure to the active area.
Thanks to our extensive experience in building ATEX-certified equipment, we implemented components and control systems compliant with all ATEX and CE directives.

Result

Results

As a result of the project, the client achieved:

full automation of a process previously performed manually,
valve cleanliness after dosing, eliminating spray head clogging,
flexible production of small batches without time loss for changeover,
reduced downtime and improved process efficiency,
safe operation in an ATEX environment, without compromising quality.

Our Approach

Each project we undertake is based on our experience across various aerosol industry segments – from standard production lines to fully automated systems for short and medium series.

In this case, the key was adapting technology to the client’s specific process, where rapid color changes, short production cycles, and absolute dosing cleanliness were critical.

In this project, the key factor was not maximum speed but maximum flexibility and minimal changeover time, which in practice determine overall production efficiency.

With frequent color changes and small batches, the ability to immediately start a new production run – without lengthy cleaning or setup – has the greatest impact on real productivity.

The client fully understood this approach, and together we designed a solution focused on producing efficiently, not just quickly.

Our goal was not to complicate the system, but to create a solution that is simpler, cleaner, and more efficient than standard market alternatives.

Through our unique Fill&Clean™ and Turn&Go™ systems, we once again demonstrated that automation – even in complex, non-standard processes – can be achieved safely, practically, and in full alignment with the client’s production needs.

Need a solution for yourself? Looking for a competent partner?

Contact our engineers! We will certainly tailor the right device for your line. Email us at sales@solmatic.pl or call +48 32 307 07 41

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