Case Study - Heatset Ink Plant, Erfurt, Germany

NETZSCH Processing and Plant Engineering deliver another Turnkey Plant

Having completed an impressive 30,000 Tonnes Gravure Ink Plant in the  UK in 2006, the engineering team at NETZSCH had an enviable track record. So when S & S Druckfarben needed a new manufacturing plant – one that would use cutting edge technology and state-of-the-art process controls to deliver a huge 35,000 Tonnes per annum - they too enlisted our services. This new production facility is the largest project of its kind in Europe since 2006 and S & S needed a company that could design the process and then engineer the new plant from start to finish, and also guarantee its final performance.

Heatset Ink Plant, Erfurt, Germany

Engineering a World Class Plant

When you are making a strategic investment, one that you have to live with for at least the next 10 years, you cannot afford to compromise. S & S needed a partner that:

  • Will engineer the process from the best available technology – not just its own.
  • Has a wealth of knowledge of wet processing technologies including mixing, pre-dispersion, wet grinding, de-aeration and filtration systems.
  • Can handle the complexity of such a large project.
  • Can apply best-of-class knowledge gained from other industries.
  • Has the laboratory facilities to validate the engineered solution prior to installation, and can guarantee the plant’s performance.
  • Has the resource to deliver against tight deadlines.
Heatset Ink Plant, Erfurt, Germany
The revolutionary Ψ-Mix® used in the plant, with a combination of vacuum dispersing, shearing and pressure wetting resulted in high productivity, with excellent results and total reproducible quality.

Making it Happen

After preliminary design studies and engineering works, NETZSCH proposed a solution using all new machinery, and the latest production technology. S & S commissioned NETZSCH in December 2006 to build and commission the new plant. 

Working from the plant performance specifications the NETZSCH engineers focused on designing the best possible solutions – utilising both their own patented machinery, like the LME Horizontal Bead Mill and the Inline-Disperser Ψ-Mix®, as well as best-in class equipment from other vendors.

From Grams to Tonnes

S & S had to be sure of the plant efficiency, reliability and output prior to installation. Using their labs in Germany, NETZSCH conducted downscale trials of the process design, and the selected equipment and process controls - validating the engineered solution and optimizing the plant’s performance and reliability. With this information, NETZSCH were able to guarantee fullscale plant performance. A guarantee NETZSCH stood behind 100%!

Pulling it All Together

From site preparation through to commissioning and final plant inspection – This was a real turnkey solution NETZSCH provided. Some of the main elements of the project included, the design and construction of new PMD batch disperser technology, upgraded LME horizontal bead mills and the revolutionary Inline Disperser Ψ-Mix®.

Mezzanine steelwork and bigbag lifting gantries; Hoists and cruciforms, big-bag and small-bag discharge units, process valves instrumentation, process pipe work with lagging, the complex electrical installation, product filters, transfer pumps, dust extraction system, fume extraction system, compressed air system, chilled water and heating system and many hundreds of smaller items.

Heatset Ink Plant, Erfurt, Germany
The LME Horizontal Bead Mills, with patented Dynamic Classifier System (DCC), provide increased throughput rates with virtually no blockage.


The final results are in... Great Ink, Consistently and Cost Effectively! Product is being delivered to S & S customers all over Europe, with consistent high quality and all the goals of the project were met including quality, throughput, cost and schedule, and reliability.  

Completed on schedule, the S & S Erfurt plant was operational in Early January 2007.