NCS Resins, South Africa’s largest manufacturer of unsaturated polyester resins, embarked on a major upgrade of its gelcoat manufacturing facility in Pinetown, KZN during March 2011. This 12 month project was successfully concluded during March 2012.
Product quality, consistency and support of NCS Resin’s sustainability policy is critical to the success of all projects. This has meant that all project works were undertaken with a high priority given to environmentally sustainable design principles.
The scope of the work included a new gelcoat reactor with new:-
- Improved natural lighting and natural air flow.
a. Allows for a better working environment.
- Efficient dual Vari-Shear
a. Able to high shear powders in shorter times.
- Improved Measuring Systems
a. Intermediate weigh tanks for pre-charge accuracy
b. Reactor and blenders on load cells for charge accuracy
- Improved Filler addition systems
a. All fillers added using a mechanised conveyor with no need to open the reactor hatch during manufacture.
- Closed additive charging point
a. All additives charged at a single point with no release of vapour
- Efficient dust and vapour extraction system
a. Reduced operator exposure
b. Reduced waste
- Imporved cooling systems with high temperature interlocks
a. Able to maintian consistent processing temperatures.
b. Mulit point temperature measurement
- Imporved Sampling
a. Ability to sample at different points to ensure consistency
- Batch size flexibility
a.This reactor has been proofed to manufacture (50% - 100%) batches.
b. Larger batches allow for improved consistency and response times.
- Increased blender capacity
a. Allows for improved utilisation of reactor
- Improved filtration
a. Reduces possibilty of rejects and customer complaints
- Improved drumming process
a. Easier handling and reduced operator fatigue.