Decorative emulsion · Western India
Viscosity drift and heavy rework on a flagship emulsion line
12% → <2%
Batch reject rate, within two production cycles
- Challenge
- Batch-to-batch viscosity was swinging out of spec, driving reblends and rejects.
- Approach
- Reworked the thickener and dispersion system and rebuilt the in-process QC checks.
- Result
- 12% → <2% — Batch reject rate, within two production cycles
The line ran a well-established interior emulsion, but viscosity was drifting batch to batch — enough that operators were reblending or rejecting a growing share of output.
We audited the associative-thickener package and the dispersion stage first, then rebuilt the in-process QC checks around the two control points that actually moved the number.
Within two production cycles the reject rate fell from around 12% to under 2%, with no change to raw-material cost.
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