Precise dosing and blending of bulk materials

BULK materials handling has improved over the years, thanks to a broad selection of equipment capable of precise feeding, dosing and blending of various types of materials. 

Coperion K-Tron has its patented Bulk Solids Pump (BSP) feeder line which has been specially designed and engineered to provide gentle, precise feeding of free-flowing pellets, granules, and friable bulk materials. The BSP feeders do not use the usual screws/augers, belts or vibratory trays to convey the material. Instead, they utilise positive displacement action to feed free flowing materials with highest accuracy, offering uniform discharge, consistent volume and gentle handling.

The BSP feeders have vertical rotating discs that create feeding ducts. Material moves smoothly from storage hopper to discharge outlet through a “product lock-up zone,” achieving true linear mass flow.With only one moving part, these compact feeders are cleaned in seconds, making them ideal for applications with frequent material changes.

Advanced control systems

Coperion K-Tron’s gravimetric batch blenders, available in various sizes from 0.5 to 25 kg total batch size and include up to eight main feed elements depending on the unit. Each unit is designed with an integrated loading platform for mounting material loaders or vacuum receivers. The blenders include an advanced metering and weighing system that accurately controls all ingredients of every batch to the desired amounts and is not averaged over multiple batches. Coperion K-Tron blenders are compact with a robust design. They are designed and constructed of heavy gauge steel to withstand the most rigorous of operating conditions. The load cell is overload protected and guarded from physical damage. All blenders include self-optimising software for the most efficient output on every recipe. Due to the continuous mixing of the bulk materials mixing times do not need to be adjusted and the consistency of every mix is ensured.

Coperion K-Tron gravimetric batch lender

The gravimetric batch blender, which will be shown at the company’s Fakuma booth, is equipped with two integrated Vacuum Receivers. The Series 2400 Vacuum Receivers are designed to high quality standards for pneumatically conveying powders, pellets, granular and recycling materials.Due to the modular design of the receivers, the material of construction, power, filtration and receiver inlet sections can be individually adjusted to meet current application requirements and future needs. Six models in several designs cover conveying rates from 330 to 6,800 kg/hr[720 to 15,000 lb/hr]. Materials of construction include aluminum, carbon and stainless steel.

The blender is also equipped with a Powder Feeder.TwinScrew Powder Feeders are designed to optimally handle difficult materials such as pigments, sticky, bridging or flooding powders, fibres and fibreglass. Coperion K-Tron's twin screw volumetric feeders are available in different sizes and a range of models cover feed rates from 0.01 dm3/hr to 1,600 dm3/hr [0.0004 ft3/hr to 45,300 ft3/hr]. Depending on the configurationthe feeders are optimised for different requirements –for fast material changes,for easy clean up or to satisfy high sanitary needs.

Another gravimetric blender model is the GRAVIMAX G56, from WITTMANN, which is a new gravimetric blender for mixing up to six different components. In spite of its large blending volume of up to 5,000 grams, this unit is on par with the highly successful smaller models from WITTMANN in terms of mechanical attributes, control system, easy access and process reliability. 

Dosing is effected by pneumatically operated, wear-resistant metering valves. The cylinders which operate the valves are located outside the material flow, which prevents the material from bridging and facilitates cleaning substantially. The special RTLS (Real Time Live Scale) weighing unit determines how often and for how long every metering valve must be activated. With this method, an impressive metering accuracy of ±1% can be achieved. To prevent falsified weighing results, the two weighing cells are mounted in a well-protected position on the outside of the appliance. The outlet flap of the weighing hopper comes with a special mechanism, which operates completely separately from pneumatic tubes and cylinders.

A special spiral blender inside the spherical mixing vessel of GRAVIMAX serves to achieve effective blending of all ingredients into a homogeneous compound.

WITTMANN GRAVIMAX G56 blender

The user interface of the new G series of appliances features an extremely clear design. The control system allows users to work with or without formulations and is able to optimise the sequence of loading the individual components automatically. Material proportions can be altered during operation. If higher material throughputs are required, identical materials can be metered simultaneously in different hoppers, which contributes to an increase in material throughput – by 30% or more.

Various responses from the blender can be selected to counteract possible malfunctions and to enhance process reliability. The SmartRegrind function, for example, prevents the processing machine from coming to a standstill just because of a lack of granulate. GRAVIMAX will supply the missing component automatically. With the help of a sequential dosing mode, the material can also be drawn from an alternative material hopper if, for example, the vessel containing the colorant has not been refilled in time. 

Redefining technical standards

The gravimetric batch blender range by Piovan, Quantum, helps improve the quality performance of production lines and redefines technical standards and market applications, delivering outstanding features of flexibility, precision, safety and efficiency. 

Quantum embodies innovations that radically change the way injection moulding machines and extruders are fed with blends of materials (virgin, recycled, masterbatch and additives).

Quantum is utilised in all application environments such as packaging, automotive, industrial and electronics, building and construction, textile, furniture, toys and housewares, medical and pharmaceutical, recycling and compounds. Its flexibility derives from two distinctive and unique characteristics. All the surfaces that come into contact with the process material are stainless steel, usable also in the most critical environments, like those found in medical and food & beverage sectors. Low roughness prevents friction and permits uniform treatment of the polymer pellets, preventing the alteration of physical conditions. Quantum therefore protects the physical characteristics of the raw material, and thereby the quality of the plastic product. ?

Also, every blender comes with up to 6 dosing stations, which can easily be removed, for emptying or cleaning. Each dosing station is dedicated to a single ingredient— be it principal or additive; easy removal therefore aids material changes and enables optimal operating conditions to be immediately resumed without contamination from powder or residue. These interventions do not require the blender to be dismantled and can be done manually by an individual operator. The dosing stations can be used across all Quantum blenders in a factory.??

The weighing pan is mounted on two load-cells, even on the more compact Quantum model. Shock absorbers, between weighing pan and load-cells, filter all possible machine vibrations to enable the load-cells to weigh the material with greater precision and mechanically protect the data transmitted to the control unit: another competitive advantage of Quantum.??

The entire batch is transferred from the weighing pan to the mixer by the dump flapper, which opens and closes pneumatically. The mixer is spherical and the mixer blade is round to fit its geometry and prevent material stagnation problems. Its strength lies in an intelligent sensor that employs the surface of the mixer as a sensitive element, needing no adjustment caused by powder, electrostatic charges, or changes in material and blend density. The sensor is an integral part of the mixer's design.  The unit is also installed with proprietary control system with 8” touch screen interface. The interface is designed to maximise intuitive use. The control panel in fact shows the operator the actual configuration of the equipment in real time, without showing redundant or unused elements. Depending on the type of production, the control system calls up the corresponding recipe and the blender automatically configures accordingly.

Piovan’s Quantum, helps improve the quality performance of production lines

The control system is designed for integration with WinFactory, the industrial supervisory software operating by application licence developed by Piovan, the outcome of consolidated knowledge in various application environments. WinFactory can interface all Quantum blenders in the factory for: sharing recipes, managing material and production batches, and tracking raw materials; these are fundamental data for product certification, in particular in food & beverage and medical-pharmaceutical environments.

The Quantum blenders are designed to be produced at all Piovan plants in the world and are part of the “High Efficiency Line”, comprising all products guaranteeing maximum energy and operational efficiency.

High volume dosing

Movacolor’s unique system functions as a full gravimetric continuous blending system

Movacolor develops and produces gravimetric and volumetric dosing units and continuous in-line blenders for injection moulding and extrusion. These systems meet the need for high volume, quality and reliability in the dosing of masterbatch, powder, regrind and liquids for producers of PET preforms toys, household goods, automotive components, packaging, medical devices, profiles, pipes, cables, sheets, film and many other products.

Movacolor’s unique modular system functions as a full gravimetric continuous blending system for outputs up to 2000 kg/hr. Up to 15 components can be controlled from one control system. And these systems can be installed on one extruder or at multiple co-extruders, creating a control platform for multiple continuous blenders in one system. The company’s systems can cover most of the available products like granulates, regrinds, powders and liquids. And all this in one system, with one standard controller and integrated loader control.

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