Introduction
A leading international machinery manufacturer partnered with Alumichem to optimize the paint detackification system on its engine painting line. The goal was to improve process stability, reduce operational costs, and create a cleaner, more efficient production environment.
Following a technical and chemical audit of the existing setup, Alumichem identified several opportunities to improve the performance of the paint system. In early 2025, the production facility began working with Alumichem, and by August 2025 the new detackification solution was fully implemented on-site.
The challenge
The production facility’s paint system operated under unstable production flows and varying loads of waterborne paint. This created the need for a highly stable, low-foam detackification process capable of minimizing sludge handling while reducing cleaning frequency.
The previous chemical program relied on bentonite-based detackification chemistry. While effective to a degree, the bentonite added significant dry matter and water retention to the sludge. As a result, sludge disposal costs increased substantially, while chemical consumption and on-site storage requirements remained high.
The manufacturer sought a more sustainable and cost-efficient solution that could reduce both chemical usage and waste generation without compromising process performance.
Alumichem’s solution
Alumichem replaced the existing chemistry with the AluTACK® program — a high-performance bio-polymer solution developed from more than 25 years of experience within industrial and automotive paint systems.
In addition to upgrading the chemistry, Alumichem recommended targeted improvements to the dosing system. These adjustments required only minimal investment while significantly improving process performance and operational stability.
Together, the optimized chemistry and improved dosing setup created a cleaner, more stable, and highly efficient detackification process.
Results
The transition to Alumichem’s AluTACK® clean water solution delivered measurable improvements across operational performance, cost efficiency, and system stability.
- More than 65% reduction in chemical consumption and on-site chemical stock
- Significantly lower sludge disposal costs through optimized dewatering and elimination of added dry matter
- Sludge dryness improved from 37% to more than 95%
- Reduced cleaning frequency and maintenance requirements
- Cleaner system water and elimination of sticky paint on flood sheets
- Improved overall process stability
- Lower total detackification operating costs
By combining advanced chemistry with process optimization, Alumichem helped the manufacturer achieve a cleaner, more reliable, and more cost-effective paint detackification system, demonstrating the value of tailored water treatment solutions for industrial painting operations.
