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Paint and Coatings Print

Raw Material Handling

Our engineering staff will study the raw materials used in the manufacturing process and select the appropriate material handling equipment. The ground hoppers above can be manually loaded or loaded from a bulk bag using a bulk bag gantry or bulk bag suspender frame. The ground hopper can be modified to handle materials with a high specific gravity or pneumatic versions are available that handle light weight fillers. The liquid additives are pumped using various metering pumps that can be accurately calibrated. These pumps are typically housed in the main control unit and fed by various sized containers.


Raw Material Metering Based On Load Cell Technologies For Liquids and Filler

In batch mixing, resin, filler and other high volume liquids (such as styrene) are added to the mix tank based on use of load cells. The load cells are placed under the mix tank and the load cell controller feeds information to the PLC control system. The PLC control system, located in the main control station, will call for the materials based on the recipe selected and the batch size desired. The operator interface is a color touch screen display.


Volumetric Metering Of Additives Such As Internal Release, Promoters, Air Release And Pigment


Recipe Based Process Control

The screens above show the menu driven recipe based control system. The operator is able to control multiple ingredients, edit and save recipes, establish operating parameters for the mixing process, select mix tanks and transfer material from the mix tank to specified day tanks. The control system will also provide daily, grand and lifetime totals for material usage. The system can be networked to allow monitoring of activity and remote troubleshooting.


Batch Mix Tanks With Mixers And Pneumatic Valves

Before selecting the mixers and tank sizes, our engineers will study your process, raw materials and output requirements. Typically, stainless steel tanks are used. Fittings for raw material delivery points, recirculation lines and output lines will be sized and placed appropriately.


In-Line Density Measurement

In-line density measurement of the matrix can be achieved through incorporation of a Coriolis Mass Flow Meter. A recirculation loop is created pulling from the bottom of the mix tank, through the Coriolis Mass Flow Tube and returning to the tank. The Coriolis Mass Flow Transmitter processes the signal from the flow tube, calculates the density and sends the signal to the PLC in the main control station. The control station software will display the density vs the target density generated by the recipe and allow the operator to adjust the mix as required. Some fillers and additives can be very time consuming to blend in a batch tank. We have addressed these issues by using a preblend unit. The preblend unit mixes the fillers and liquids to be used in the batch together. This mixture can be pumped to the mix tank and combined with the remaining fillers and additives called out by the recipe.


Automatic Transfer Of Material Flow From Mix Tanks To Day Tanks

Typically, a mix tank is used with one or more day tanks. Use of a mix tank and a day tank allows a completed batch to be transferred to a day tank and a new batch to be made in the mix tank. Conversely, the matrix in the day tanks can be moved back to the mix tank to serve as the starting point for new batches. Automatic transfer of matrix between mix tanks is accomplished by using pneumatic valves and pumps. The operator is able to specify through the touch screen display, what path the material needs to take. Once selected, the solenoid valves open/close to actuate pneumatic valves and pumps.


Control Of Recirculation Lines Between The Tanks And Dispense Head

Recirculation lines are run from the day tanks to the dispense head. Pumping material through the recirculation lines provides instant material availability at the dispense head. The matrix delivery pump ensures continuous flow of matrix to the matrix metering pump. The matrix metering pump provides matrix to the dispense head at a controlled rate.


Metering Pumps Capable Of Providing Material To The Dispense Head

The dispense head receives material from the matrix metering pump, adds catalyst, mixes and dispenses the material in a controlled manner.  The matrix can be dispensed in manually via foot pedal or can be taught the amount to dispense in automatic mode.  The design of the mix head will also minimize the amount of air entrapped in the matrix.  Periodically, the dispense head will need to be cleaned using the recycled and virgin cleaning material stored in the tanks at the bottom of the unit.