PT Impack Pratama Industri Tbk: Custom Automated Water-Based Coating Line for Eco-Friendly Roofing & Building Materials
Industry: Building Materials & Polymer ProductsLocation: IndonesiaCoating Application: Fully automated spraying line for plastic roofing sheets, corrugated panels, and exterior wall products (water-based paint, UV, water-based UV, and PU coatings compatible)Line Length: Custom-designed ~20m line with European-style safety structure for high-volume production
Client Overview
Founded in 1981, PT Impack Pratama Industri Tbk is Indonesia’s leading manufacturer of innovative building materials, including uPVC roofing, aluminum composite panels (ACP), polymer resins, adhesives, sealants, and packaging materials. With a strong commitment to sustainability, the company integrates recycled materials into its core products:
- ECOLITE roofing: ~761 tons of recycled PET (≈48 million plastic bottles)
- ACP panels: ~1,192 tons of recycled LDPE/HDPE (≈217 million plastic bags)
- Impraboard: ~408 tons of recycled PP (≈136 million plastic cups)
To elevate surface finishing quality, enhance eco-friendly production capabilities, and meet growing demand for durable, aesthetically appealing polymer building materials, Impack partnered with PURETE to deploy a custom automated painting line.
Project Challenges & Goals
Before implementing the new PURETE line, Impack faced key production hurdles:
The primary goals of the partnership were:
Automate water-based coating application for plastic roofing sheets and exterior productsReduce labor costs, paint consumption, and VOC emissions
Achieve flexible, high-volume production with consistent, high-quality finishes
Support the company’s sustainability strategy while boosting product durability and weather resistance
Custom PURETE Automated Coating Line Solution
PURETE delivered a tailor-made, fully automated spraying line optimized for Impack’s unique production needs, combining European-style structural design with advanced safety systems. The line is engineered for:
- Roofing & building material applications: Ideal for plastic roofing sheets, corrugated panels, exterior wall panels, and related polymer products, with compatibility for UV, water-based UV, water-based paint, and PU coatings
- Multi-sector versatility: Adaptable to furniture, flooring, cabinets, wardrobes, wooden doors (solid wood/engineered/fire-rated), door frames, and moldings
- High-volume, batch production: Built for continuous, large-scale manufacturing while supporting flexible multi-color, multi-batch customization
- Compact footprint: Custom ~20m length designed to fit Impack’s factory layout, with scalable configurations available based on site requirements
Key Line Components & Features
| Component | Details |
|---|
| Reciprocating Spray System | High-performance reciprocating spray machines ensure uniform coating coverage, even on irregular roofing and panel surfaces |
| Circulating Paint Supply System | Reduces paint waste by recycling excess coating material, cutting material costs and minimizing environmental impact |
| Automated Drying Section | Integrated drying module ensures fast, consistent curing, eliminating bottlenecks in the production workflow |
| European-Style Safety & Control System | Comprehensive safety features, automated process monitoring, and easy maintenance access for reliable, long-term operation |
PURETE Production Line Model Comparison
The table below highlights the specifications of PURETE’s core automated spraying line models, including the custom solution deployed for Impack:
| Specification | P1 Line | P2 Line | P3 Line | Impack Custom Solution |
|---|
| Core Application | General wood/board materials | Medium-to-high volume building materials | High-volume industrial production | Plastic roofing sheets, corrugated panels, exterior wall products |
| Compatible Materials | MDF, particleboard, eco-board, PVC board, melamine paper-laminated substrates | Same as P1 + polymer building materials | Same as P2 + heavy-duty industrial panels | Plastic roofing sheets, polymer panels, custom building substrates |
| Compatible Coatings | UV, water-based UV, water-based paint, PU | UV, water-based UV, water-based paint, PU | UV, water-based UV, water-based paint, PU | Water-based paint (primary), UV, water-based UV, PU |
| Total Power | 109 kW | 124 kW | 96 kW | Custom-tuned for 20m line footprint |
| Air Consumption | 3 L/min | 1200 NL/min | 1420 NL/min | Optimized for Impack’s production scale |
| Installation Footprint | 50×7 m | 38×4×3 m | 37×7.6×5 m | Custom ~20m line (adapted to factory layout) |
| Production Cycle | 35 days | 50 days | 90 days | Custom lead time based on site requirements |
| Labor Requirement | 3–5 operators | 3–5 operators | 3–5 operators | 3–5 operators (automated process reduces manual tasks) |
| Line Speed | 3–6 m/min | 3–6 m/min | 3–6 m/min | 3–6 m/min (adjustable for roofing/panel sizes) |
| Daily Production Capacity | 800 m²/8h | 800 m²/8h | 2000 m²/8h | Scalable based on Impack’s production goals |
| Coating Cost | 5–10 RMB/m² | 3–8 RMB/m² | 3–8 RMB/m² | Reduced paint consumption lowers per-unit coating costs |
| Gloss Range | 5–100 Gu | 5–100 Gu | 5–100 Gu | 5–100 Gu (customizable for roofing/exterior finish requirements) |
Results & Business Impact
Since deploying the PURETE automated coating line, Impack has achieved significant improvements across its production and sustainability metrics:
Enhanced product quality: Uniform water-based coating application improves weather resistance, surface adhesion, and aesthetic appeal of roofing and building materials
Sustainability progress: Reduced VOC emissions, lower paint consumption, and automated processes align with Impack’s circular economy goals
Production scalability: High-volume line capacity enables Impack to meet growing demand in Indonesia and Southeast Asia, with flexible multi-color/batch capabilities for custom orders
Operational efficiency: Reduced labor dependency and simplified maintenance lower long-term production costs
Compliance & market expansion: Eco-friendly, high-quality finishes help Impack meet regional environmental standards and expand its premium product portfolio
Looking Forward
The partnership between PURETE and Impack demonstrates how custom automated coating solutions can drive sustainable growth in the building materials industry. Impack continues to leverage PURETE’s advanced surface finishing technology to upgrade its product offerings, while PURETE remains committed to supporting regional manufacturers with tailored, eco-friendly production solutions.
Why Choose PURETE for Your Automated Coating Needs?
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