Problem Solving
Automatically produce exterior paint and reliably feed the dissolver
In automated bulk material handling for the production of exterior paints, powdered raw materials are processed automatically from storage to the dissolver feed. Bulky materials such as chalk are transferred directly from silo trucks into the storage silos; alternatively, big-bag unloading stations can be used. This allows different raw material sources to be integrated into a continuous conveying process.
Precise dosing for reproducible formulations
Vibrating floors, aeration membranes, and frequency-controlled dosing screws ensure controlled discharge and dosing. The raw materials are transported via vacuum conveyors to weighing hoppers, where they are precisely weighed. This enables the reproducible production of batches with weighing accuracies ranging from ±50 g to 3 kg and a batch tolerance of ±3 kg.
Flexible Dissolver Feeding and Documented Production
The weighing hoppers can be flexibly routed to the downstream dissolvers via pipe switches. The pressure-fed conveying system achieves a capacity of up to 15 t/h and bridges conveying distances of up to 90 m. This enables flexible feeding of the dissolvers while maintaining high plant throughput. Batch records document the process from raw material storage to dissolver feeding; recipe management in the Kastor process control and visualization system supports safe and efficient production.
Problem Solving
Automatic Dosing and Mixing of Powder Coatings
The automated bulk material handling system for powder coating production integrates silo-stored material, big bags, and bagged material into a single automated raw material supply process. Depending on the volume share and delivery containers, the raw materials are stored in outdoor silos or fed directly into the process from big bags and sacks. This allows different quantities and types of raw materials to be processed within a continuous production process.
Precise Weighing for Reproducible Formulations
The raw materials are transported to the automatic weighing station via vacuum or suction conveyance. Big bags and bagged materials are weighed into the mixing container via feed hoppers and frequency-controlled dosing screws. Depending on the recipe and the required accuracy, weighing is performed either additively or via upstream weighing hoppers. This achieves weighing accuracies between ± 50 g and ± 1 kg and ensures that recipes are prepared consistently.
Automated Mixer Feeding with Documented Batches
The AZO COMPONENTER® handles the centralized weighing of the formula into the mixing container. Once the batch is complete, it is fed into the mixing process. Batch logs document the process from raw material storage to mixer feeding. Formula management in the Kastor process control and visualization system supports safe production and efficient utilization of the plant and container mixer.
Problem Solving
Producing Toner That Is Contamination-Free and Precise
In toner production, automated bulk material handling provides a closed-loop process control system tailored to the fine, differently pigmented raw materials. Big bags and sacks are automatically fed into the system and assigned to the respective formulations. This enables a controlled feed of raw materials for toner production.
Precise weighing for varying quantities of raw materials
Big bags are connected to the discharge stations via dust-tight connection systems. Vibrating tables, agitation devices, and metering screws ensure reliable discharge and dosing. Bagged materials are fed via filling hoppers and weighed either as a subtraction or addition, depending on the proportion of the batch. This allows the components to be dispensed with weighing accuracies ranging from ± 100 g to ± 2 kg for the respective formulation.
Formula Accuracy Through Separate Bulk Material Containers
The BATCHTAINER® collects the raw material components according to the assigned formula. Since the bulk material containers are permanently assigned to specific formulas, potential contamination between different color pigments is prevented. Roller conveyors in the delivery and receiving areas buffer the containers, thereby supporting high throughput of the automatic weighing system. The fully filled containers are then fed into the mixing and filling process.
Documented Processes for Safe Toner Production
The Kastor process control and visualization system handles formula management and supports the safe and efficient utilization of the plant, mixer, and filling line. This enables centralized control of the automated process from raw material preparation through to further processing.
