Project Location: Ethiopia
Target Product: Solvent-Based Gravure Ink
Production Capacity: 200-300 kg/hour (1,600-2,400 kg/day)
Project Time: August 2024 - March 2025
Customer Challenge
The customer needed a complete production line for solvent-based gravure ink with the following requirements:
- Material viscosity: 5,000-8,000 CPS
- Production capacity: 200-300 kg/hour
- Grinding fineness below 5 microns
- Complete line from pre-mixing to grinding
- Dust and odor removal system required
POLYC Solution
POLYC MACHINE configured a complete gravure ink production line:
- Pre-Dispersing: 22 kW High-Speed Disperser with 2x 1,000L movable tanks
- Emulsification: 22 kW High-Shearing Emulsifier with 2x 1,000L movable tanks
- Fine Grinding: 20L Pin-Type Bead Mill with 2x transfer tanks
- Environmental: Dust collector and odor removal system
Results
With POLYC technical drawings, installation guides, electrical diagrams, operation manuals, and video tutorials, the customer successfully installed and operated the production line independently. All machines perform well, with grinding fineness reaching 2 microns and excellent colour strength. Shipment completed in October 2024; installation and production started in March 2025.
Industry Context
Ethiopia's printing and packaging sector has expanded rapidly with the growth of local manufacturing and consumer goods industries. Solvent-based gravure inks demand precise particle size control—typically below 5 microns—to ensure consistent print quality, colour strength, and transparency on flexible packaging substrates. The high solvent content requires careful attention to explosion protection and emissions control throughout the production process.
Technical Highlights
| Parameter | Specification |
|---|---|
| Product | Solvent-Based Gravure Ink |
| Production Capacity | 200-300 kg/hour |
| Material Viscosity | 5,000-8,000 cps |
| Target Fineness | Below 5 microns (achieved 2 microns) |
| Pre-Dispersing | 22 kW High-Speed Disperser |
| Emulsification | 22 kW High-Shearing Emulsifier |
| Fine Grinding | 20L Pin-Type Bead Mill |
Engineering Approach
The production flow follows a three-stage wet grinding pathway: pre-dispersion with a high-speed disperser to wet pigment agglomerates and reduce particle size to approximately 20-30 microns, followed by high-shear emulsification for further deagglomeration, and final fine grinding in a pin-type bead mill using zirconia media. The pin-type configuration provides higher energy density than disc-type mills, making it suitable for achieving sub-5 micron fineness in viscous ink formulations. Movable tanks allow flexible production scheduling between stages, while the dust collector and odor removal system maintain a safe working environment for solvent-based operations.
Process Design Rationale
The Ethiopia configuration follows the three-stage logic of solvent-based gravure ink: wet-out, emulsification and fine grinding. A 22 kW high-speed disperser handles wet-out at 5,000-8,000 cps, where the material is still thick enough that a low-power unit would simply rotate in a cavity rather than circulate the batch. The high-shearing emulsifier then works the resin and solvent phase before grinding, so the bead mill receives a pre-broken-down suspension instead of doing both jobs.
The 20L pin-type bead mill is matched to 200-300 kg/hour. A larger chamber would add residence time and heat but not throughput, because the limiting factor at this viscosity is the mill's ability to keep product moving past the pins, not chamber volume. Two 1,000 L movable tanks at each stage let the operator prepare the next batch while the current one is being ground - the practical way to keep a small-batch line busy without adding a second mill.
Quality and Acceptance Checks
Solvent-based ink acceptance typically covers fineness of grind, viscosity, colour strength and solvent resistance of the contact materials. In this project the specified target was below 5 microns, and the installed line reached 2 microns. Beyond the product tests, two equipment checks matter on solvent lines: confirmation that the dust collector and odour-removal system hold the working area within the agreed limits, and verification that electrical and mechanical components are rated for the solvent present. Both should be witnessed before shipment, not after installation.
Specifying a Similar Line
For a comparable gravure ink project, the specification should state hourly output and shift pattern, viscosity at working temperature, target fineness, solvent type and flash point, tank mobility and available floor space, and the required level of automation. Solvent handling also determines the explosion-protection class of motors and controls, and whether nitrogen blanketing or additional ventilation is needed. Raising these points early avoids reworking a layout that was drawn around the wrong safety class.
Related Equipment
Explore the equipment configured for this line: Pin-Type Bead Mill, High-Speed Disperser, and High-Shear Emulsifier.
Recommended equipment
Pin Type Bead Mill is the relevant POLYC MACHINE configuration for this application.