Problem Solving
Turnkey system for the base stabilization of PP powder
AZO integrates raw material handling, homogenization, dosing, and extruder feeding into a single, continuous process. The system is designed for unstable polymers susceptible to oxidation and to meet ATEX requirements. Conveying under nitrogen protects the material while also enabling safe transport over conveyor distances of approximately 400 meters. Recirculating the nitrogen minimizes losses.
Homogenization for Consistent Product Quality
The base polymer is fed through several homogenization silos, mixed, and then weighed again. This homogenizes the material multiple times before it is fed into the extruder. This reduces variations in the raw material and creates a more uniform base for further compounding.
Precise dosing and continuous extruder feeding
AZODOS® differential feeders continuously feed polymer and additives into the extruder. The additives are supplied from big-bag and bag-discharge stations. This ensures a continuous supply of raw materials—with defined components—to the extruder.
End-to-End Control and Process Reliability
The process control and visualization system, together with the PLC, handles the control, monitoring, and documentation of the plant. The ERP integration enables end-to-end order processing and documentation. Remote maintenance and a 24-hour maintenance contract further support the plant’s high availability.
Problem Solving
Bulk material handling during the compounding of a wide variety of materials (fiber-reinforced) with maximum flexibility and manual premix production
AZO designs flexible bulk material handling systems for the compounding of various engineering plastics. Raw materials from silo trucks, containers, big bags, sacks, and mixing vessels can be processed within an integrated plant design and fed to the compounding lines as needed. This allows the raw material supply to be adapted to different manufacturing processes and product variants.
Reliable Conveyance and Precise Dosing
Pneumatic suction conveying systems transport the raw materials to the separators located above the extruders. Large and medium-sized components, glass fibers, and premixes are then fed into the extruder via differential feeders. Specific solutions for abrasive raw materials enable conveying that is tailored to the material properties.
Clean conveyance of finished goods and easy product changeovers
After compounding and pelletizing, the pellets are screened and transported via vacuum conveying to daily storage silos. A metal separator removes any metal residues from the material stream. The design of the material conveying system and the various feeding stations ensures reliable operation even when products change frequently.
Traceable Processes
The combination of feeding stations, dosing technology, and a production control system enables the structured processing of various raw materials. This provides the operator with a flexible plant solution for a wide range of compounding processes and allows them to adapt the supply of raw materials to changing production requirements.
Problem Solving
Bulk material handling with the widest variety of components, the highest level of automation, and a zero-defect strategy
To manufacture cable compounds, AZO combines automated bulk material handling with precise dosing and end-to-end process control. Especially when dealing with a wide variety of formulations and raw materials, the automated delivery of components reduces manual effort and supports reproducible production.
Processing Many Raw Materials Safely and with Traceability
The AZO DOSINENTER® enables the automated dispensing of medium- and small-volume components for the production of premixes. The system can automatically feed more than 20 formulations—comprising a total of approximately 200 different raw materials—into the mixing process. Barcode identification and an audit trail enable end-to-end tracking of containers and process steps.
Precise dosing for consistent formulations
Large components, premixes, and micro-components are continuously fed to the compounder via AZODOS® differential feeders. This allows the various formulation components to be metered according to process requirements. Micro-dosers also enable the weighing of very small quantities.
Gentle handling of finished goods and automated filling
The finished granules are gently conveyed to storage silos via the AZO®MULTIAIR system. Circulating conveyance, silo headspace drying, and lump breakers help maintain the quality of the finished product all the way through to filling. The automatic positioning of the filling crates reduces manual process steps and enables a high degree of automation.
End-to-End Process Control and Documentation
A process control and visualization system, along with a PLC, control, monitor, and document the compounding process. Orders can be imported and confirmed via the ERP interface. Recording production parameters also creates a traceable process history.
Problem Solving
Bulk material handling during the compounding of a wide variety of materials (fiber-reinforced) with maximum flexibility and manual premix production
AZO integrates product feeding, premixing, dosing, and conveying into a seamless bulk material handling system for the compounding of highly filled polymers and masterbatch. Powdered raw materials such as chalk and additives, as well as granules, can be fed into the closed system from various containers. The low-dust feeding process reduces contamination during raw material feeding.
Precise premixing for consistent extruder feeding
The AZO®MIXOMAT handles both mixing and vacuum weighing. This allows components to be precisely metered and prepared as a premix. While one premix is being fed into the extruder, the next one can already be prepared. This supports a continuous production process.
Continuous dosing in accordance with the extrusion process
AZODOS® differential feeders continuously feed the various components into the extruder. The feeding rate is determined by the extruder. This links the feed of raw materials to the ongoing extrusion process and enables precise metering of the materials used.
Gentle handling of the product all the way through to filling
After granulation, the finished product is gently conveyed to the big-bag filling station. The end-to-end control, monitoring, and documentation of the process via the AZO process control and visualization system supports traceable and controlled production.
