Our highlights at European Coatings Show 2019

in Nuremberg hall 6, stand 331

AZO, the expert for automatic raw material handling of powders, additives, pigments, fillers and liquids, is one of the exhibitors at ECS 2019.
 
In hall 6, stand 331, the AZO Group will be demonstrating solutions for automatic handling of large and medium components and the integration of small components and ingredients in the automated process.

 
Appointment

At our trade fair stand you can find out more about the following key themes:

AZO, the specialist for automatic raw material logistics of bulk solids and liquids, presents its latest plant technology at ECS 2019: AZO®RoLog 2.0. The system automates the dosing process of very small quantities using a combination of the latest AZO technology and proven robotics.
 
The dosing of small quantities up to 10 kg has hitherto mostly been carried out manually by an operator. Each component of a recipe has to be weighed by hand and introduced into the existing production process. This can be a problem for the operator and product safety, especially for highly critical or harmful substances in the pharmaceutical, chemical or food industry. Such substances are only manageable under special protective measures. In addition, there is the risk of not being able to reproduce complex formulations exactly.
 
Against this backdrop, AZO developed the solution and presented: AZO®RoLog. In this system, the raw materials are automatically loaded or unloaded by a robot and a specially developed dosing device takes care of the exact dosing of the individual components. In version 2.0, further improvements to the dosing devices and the entire periphery could be implemented cost-effectively.
 
AZO®RoLog - automatic dosing of minor quantities
The raw materials, for example pigments, flavors, additives, agents, etc. are supplied in dosing and storage units (DLE) provided for further automatic processing. A safety cell separates the automation area (working area of ​​the robot) from the production environment. This manless raw material logistics offers an optimum of protection for the operator and the product. The modular structure of the raw material storage module (RLM) also ensures high flexibility in the expansion of raw material components.

The robot automatically assembles the batch by providing the correct DLEs according to the given recipe. From these DLEs, the required small quantities get removed at the metering point and get dosed accurately. This leads to reproducible dosing results in the range of 50 g to 10 kg. After weighing all components in the target container, this is delivered to a buffer area and then provided for further processing.

AZO®RoLog is now ready to process additional production orders. Thus, the system works efficiently and without losing time. A cost-efficient and flexible 24/7 production is possible if a continuous supply of raw materials and containers is ensured. The AZO®RoLog system can be operated as a stand-alone version or integrated into a fully automated process.
 
The hopper serves to feed bulk solids in powdered and granular form into closed materials handling systems, such as pneumatic conveying systems. Products can be fed from sacks, boxes, barrels or similar receptacles. As different branches will have very diverse requirements regarding quality and hygiene, the feeding hoppers are available in a variety of materials and surface finishes.
 
After opening the lid to the feeding hopper, the aspiration process of the interior starts, thus preventing dust from escaping while the product is poured in. Depending on the requirements, dust filtration can be implemented either via an attached individual filter with built-in filter cleaning or via a central filter station. To assist discharge of bulk materials with poor flow properties, the feeding hoppers have been fitted with rappers, vibrators, bin activators or aeration jets. The design can be adapted to downstream equipment such as rotary valves or dosing screws by using appropriate flanges for an optimum fit. Installation is carried out according to customer requirements using support brackets, consoles or in a separate frame.
 
An integral vibrating perforated sheet prevents packaging residue and other unwanted coarse material from entering production. The layout of the vibration motors and vibration elements and their direction of rotation cause the product to flow in a defined direction on the screen. Coarse particles that are larger than the screen mesh size are conveyed to the coarse material outlet and evacuated there. The inclination and intensity of the vibration motors can be varied to adapt them to accommodate each product. The circular screens are available with a polyester/plastic fabric in mesh sizes of 2 to 5 mm or with special metal screens in a range of mesh sizes with a maximum actual screening area and with no risk of wire rupture.
 
All operations at the new feeding hopper, such as filling, screen inspection, removal of coarse materials and screen replacement, are carried out from one side. It is quick and easy to replace screens using standard tools.
 
Throughput rate varies depending on the product and mesh size. The following throughput rates can be used for reference purposes: 4500 kg/h wheat flour with a mesh size of 3mm, 1700 kg/h powdered milk with a mesh size of 5 mm.
Feeding hopper with integrated vibrating perforated sheet and automatic evacuation of coarse materials
Feeding hopper with integrated vibrating perforated sheet and automatic evacuation of coarse materials
AZO cyclone screeners combine operationally safe technology with high performance and easy maintenance and cleaning. The screeners can easily be integrated into existing systems thanks to their compact design. The tried-and-tested, inexpensive cyclone screener type E is available both in painted version and in stainless steel.
 
Typical areas of application include:
  • control screening before and during processing to ensure that no impurities, e.g. bag fibres, lumps and scraps of paper, get into production.
  • control screening together with a metal detector prior to filling and packaging to ensure that no foreign matter remains in the finished product.
  • breaking up agglomerates that can occur in bagged goods or hygroscopic bulk solids. The lumps are carefully broken up without any loss of product.
  • separation of agglomerates following drying processes.
  • fractionation of bulk solids in powder form into assorted fractions according to particle size.
Control screening before and during processing to ensure that no impurities, e.g. bag fibres, lumps and scraps of paper, get into production
AZO cyclone screening with ultrasonic assistance
For certain application areas the use of ultrasonic is useful. Sonic pulsing of the screen mesh can be used or fitted retroactively in the AZO type E, DA, FA and RA cyclone screeners.
 
Key advantages:
  • Increase in screening capacity
  • Improvement in selectivity
  • Longer times between cleaning
  • Straightforward retrofitting in existing machines
  • Converter is outside the screener and hence outside the flow of powder.
 
The use of ultrasound causes the stainless steel screen to vibrate at high frequency. These minute vibrations prevent near-size particles from sticking in the mesh of the screen fabric. The screen mesh stays clear for longer, which in turn noticeably improves selectivity. This may result in an increase in screen capacity. The screen basket needs to be removed for cleaning far less often and this significantly increases the useful life of the machine.
 
Cyclone screener with mounted ultrasonic converter
Cyclone screener type E360 with ultrasonic pulsing of screen mesh
  • Kastor process control and instrumentation system – plant controls and visualisation
      plant controlling, visualising and logging

    Combination of the innovative development Kastor process leading system with a visualization on basis of standard tools, results in a central process leading and visualization system having the ability to carry out a multitude of workflow controls and checks.
    Furthermore this central system offers a complete documentation of production sequences – e.g. by batch reports, yield balances and a long-term archivation of collected data. In addition it offers an individual configurable access protection.
     
  • Kastor T&T – tracking & tracing throughout your production workflow
      so you have all the data immediately to hand when the need arises

    Our solutions for documenting production and hence for batch tracing guarantee transparency, safety and reliability. In addition, barcode identification of the raw materials allows for a validity check during the production process.

    The raw materials and intermediate products are identified using barcodes or RFID throughout the entire production process and are tracked through the plant. All weighing operations are recorded and associated with the end product in the data system. In the event of a problem with the quality of a raw material, our process control systems can provide a full list of the stages in production, meaning that every raw material can be tracked from incoming goods through to the end product.
 
  • Kastor DataCockpit – new functions for analysing data
      providing even greater transparency for plants and demonstrate the potential for improvements

    Generally speaking, data analysis involves deriving useful findings from data. To do this, various techniques are used to restructure, organise and present the data, so that relationships and dependencies in the data become visible and the results can be used as a basis for production optimisation. Data analysis itself can therefore be classified as a dedicated method or technology within the context of improving production systems.
    One very important issue when dealing with production data is that of data security. All technologies must be implemented from the perspective of maximum security to ensure that highly sensitive production data are also handled securely.
    Kastor DataCockpit bring new insights into potential for optimisation, highlighting possible weak points or how to prevent faults – data analysis provides our customers with a solid foundation for permanent improvement of their AZO system or system components.​​​​​​​
     
  • Kastor HostLink – interfaces to ERP systems
      supporting optimum integration into your business world

    ​​​​​​​If a universal interface software is to be used for the connection of control systems to ERP such a software must be very flexible due to the diversity of data types to be exchanged and due to the many different storage variants.
    ​​​​​​​To connect your plant control to the ERP system, HostLink is used as a Software Gateway. Production orders are transferred from ERP to control, production results are reported back to ERP. This ensures a seamless integration of production into the business-IT-world.