Phase 1: Rohtak Automation Program Asian Paints System Overview: For more information, visit bastiansolutions.com or call (800) 772-0464 Asian Paints has set up its sixth largest decorative paint plant at Rohtak, Haryana. This state of the art paint plant is located at Industrial Model Town developed by Haryana State Infrastructure and Industrial Development Corporation. With a production capacity of 400 million liters of paint every year, this plant is one of the largest in the world. Following the completion of the four-phase project, Asian Paints hopes to be the largest paint plant in the world with a final production capacity of 400,000 kl/year. System Overview:
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Phase 1: Rohtak Automation Program
Asian Paints
System Overview:
For more information, visit bastiansolutions.com or call (800) 772-0464
Asian Paints has set up its sixth largest decorative paint plant at Rohtak, Haryana. This state of the art paint plant is located at Industrial Model Town developed by Haryana State Infrastructure and Industrial Development Corporation. With a production capacity of 400 million liters of paint every year, this plant is one of the largest in the world. Following the completion of the four-phase project, Asian Paints hopes to be the largest paint plant in the world with a final production capacity of 400,000 kl/year.
System Overview:
Asian Paints
For more information, visit bastiansolutions.com or call (800) 772-0464
Phase 1: Rohtak Automation ProgramBusiness Challenges:• Asian Paints wanted to distribute directly to their dealers from its
new 130-acre facility in Rohtak (close to New Delhi).
• Bastian Solutions was tasked to design a packaged materials and
finished goods ASRS with conveyors and lifts that would allow Asian
Paints to expand in four phases over the next 4-5 years.
• The new system had to handle an anticipated volume of 264 pallets
per hour, fully automated and controlled using a WCS system.
Key Technologies:• Pallet conveyors
• Bar code scanners (Datalogic)
• Exacta software (Bastian Software Solutions)
• APL host SAP system
• Bastian Software Solutions controls and human machine interface
(HMI) data displays
• Automated storage machines (Swisslong-Accalon)
• Onboard camera system to monitor pallet transfers
• Double-deep storage rack (BITO)
• S32 single mast ASRS cranes (Vectura)
• Depalletizers (SIPAC)
• Denester units (Heisler)
• Vertical lift units (Gebhardt)
• Transfer cars to service pallet flow lanes (Gebhardt)
• Exacta truck dock monitor system (Bastian Software Solutions)
• Gravity flow lanes (BITO)
Results:• Able to successfully help Asian Paints implement phase 1 full pro-
duction within 3-4 months of project handover.
• Asian Paints is positioned to grow order volume (phase 2-4) without
adding additional labor.
• Stock accuracy, productivity, and throughputs have increased dra-
