Production of Emulsion Paints with Colloid Mills

Emulsion paints cover a vast spectrum—from dead-matt interior wall coatings to high-gloss façade finishes. To deliver the required coverage, gloss level and abrasion resistance, pigments, fillers and binders must be dispersed extremely finely and absolutely uniformly. At the same time, viscosity must remain under tight control during both mixing and application, while excessive air or foam is fatal to shelf life. This is precisely where PUC colloid mills excel.

Effective one-step dispersion

Inside the rotor–stator system the product passes through a continuously adjustable annular gap. Cutting, impact, friction and shear forces act simultaneously, breaking down pigment and filler agglomerates at once—one cycle is often enough to achieve the specified particle-size distribution. Energy consumption and cycle times fall accordingly.

Wide viscosity window – from primer to textured render paste

PUC mills process formulations from <100 cP up to 80,000 cP paste consistency. Throughput and shear intensity can be matched precisely to the specification by selecting machine size, gap setting, and—if required—an integrated recirculation module.

Process reliability and hygiene

• Choice of single- or double-acting mechanical seals or PTFE lip seals simplifies switching between water-borne dispersions and solvent-based specialty coatings
• Heat- or coolant-jackets keep temperature under control, minimise skin formation, and ensure consistent viscosity
• A closed inline configuration prevents foam ingress and facilitates the integration of modern degassing or defoaming stages

Complete drainability and easy cleaning

Vertically mounted process chambers empty automatically; horizontal versions feature low-point outlets—only a few grams of residue remain. Shade or batch changes are faster and waste is significantly reduced. All product-contact parts can be given a high-polish finish, are CIP/SIP-capable, and have quick-release fittings. Rotor–stator sets can be removed, inspected, or changed in minutes.

Scalable from laboratory beaker to full production line

Formulation work on the PUC 60 laboratory model starts with identical shear geometry. After scale-up, Series O and E deliver up to 34 m³/h, while EL mills reach 80 m³/h—without specification adjustments or additional approval loops.

Decades of cross-industry experience

Since 1926, Probst & Class have built colloid mills for virtually every branch of the processing industry—from chemicals, paints and coatings to food, cosmetics, pharmaceuticals,and petrochemicals. This breadth of know-how informs every design detail, making PUC mills dependable components in both new and existing production lines.

Investment security and low total cost of ownership

PUC have supplied spare and wear parts for decades, irrespective of a machine’s year of manufacture. Reliable parts availability, rugged stainless-steel construction, and energy-efficient drives keep your total cost of ownership low and shrink the ecological footprint of your business.

Advantages of emulsion paint processing

• Maximum coverage and colour stability thanks to narrow particle-size distribution
• Uniform gloss and abrasion values through homogeneous pigment and filler dispersion
• Reliably reproducible viscosity—from low-viscosity primers to high-build textured paints
• Minimal material loss due to almost complete drainage.
• Short cleaning and changeover times—greater line availability with frequent colour changes
• Long-term parts availability safeguards investment and lowers TCO
• Sustainable inline workflow: reduced energy consumption, lower VOC emissions, no open vessels
• Seamless scale-up: identical shear geometry from initial development to the 80 m³/h production line

With a colloid mill from Probst & Class you invest in more than a machine—you acquire a process-secure, sustainable plant component for the economical, eco-friendly manufacture of high-quality emulsion paints.