Our Work

Industry

• Paint and Coatings Manufacturing

Client profile

• Annual revenue: HUF 28 billion
• 380 employees

Project period

• Q1 2026

Project duration

• 9 weeks

Technology decision context

• Development of the industrial manufacturing concept for a new multi-component paint and coatings product line.

Project scope

• Harmonisation of manufacturing workflows for multiple formulations
• Handling of different liquid and powder components
• Integration of raw material handling, dosing and mixing processes into a unified production system
• Development of transfer, buffering and pre-packaging storage logic
• Definition of process unit interconnections and the fundamental plant layout logic

Challenge

The client was preparing to industrialise a new multi-component product portfolio to be manufactured on a single production line. Although the overall technological direction had already been identified, there was no structured decision-making framework for transforming individual engineering concepts into a single, transparent and operationally efficient technological process system.

Individual process elements—including raw material handling, liquid and powder dosing, mixing, transfer operations, buffering and pre-filling storage—had already been considered. However, they had not yet been integrated into a coherent process architecture capable of supporting detailed engineering and investment decisions.

Several technological and process design alternatives were under evaluation, many of which carried considerable technical, operational, capacity and commercial risks. An incorrectly designed concept could have resulted in production bottlenecks, inefficient material handling, oversized or improperly located equipment, unnecessary buffer capacity and costly redesign during later project phases.

Adaptum’s role

The objective of the project was not to produce detailed engineering documentation or select specific equipment. ADAPTUM was engaged to develop the pre-investment technology concept and provide decision support. Our work included:

• analysing the manufacturing logic of the planned product portfolio
• evaluating the process requirements of the different formulations and liquid and powder components
• assessing the interdependencies between raw material handling, dosing, mixing, transfer and buffering operations
• identifying which process steps could be standardised across the entire product family
• determining where dedicated handling or dosing solutions were required for individual product variants
• analysing the spatial and functional relationships between process units
• eliminating overly complex, operationally inefficient or commercially high-risk system concepts
• developing a unified and objectively comparable technology concept to support the next phase of engineering

Results

• By the end of the project, the client had transformed a collection of isolated engineering concepts into a clear, integrated and operationally viable production system.
• The previous uncertainty was replaced by a technology concept that was both technically robust and commercially defensible.
• The concept development process clearly defined which process units should be directly connected, where intermediate storage or buffering was justified, and which overall plant layout best supported efficient production.
• The client received a comprehensive PDF concept study that served as a decision-support document by presenting:
• • the overall process architecture,
  • the material flow concept,
  • the relationships between the major process units,
  • the fundamental plant layout philosophy,
  • and a simplified visual representation of the complete production system.
• The documentation provided a significantly clearer understanding of system complexity, the logical sequence of the subsequent engineering phases and the operational and investment implications of each decision.
• Rather than progressing on the basis of individual technical solutions, the client was able to continue detailed engineering using a single, integrated and commercially validated technology concept.

Business impact

The project was not about selecting new equipment.

By developing the technology concept before detailed engineering and procurement began, ADAPTUM enabled the client to eliminate technically and commercially unsound design decisions that could have led to oversized equipment, unnecessary buffer capacity, inefficient material flow or costly redesign during implementation.

The resulting concept significantly reduced the risk of future investment and engineering modification costs and engineering modifications that, according to expert estimates, could otherwise have generated additional costs of approximately HUF 15–18 million.