Planning metering and mixing systems correctly

What is important? How do you avoid the most common design errors?

"We need a dosing system, could you offer us something...". We receive these and similarly worded enquiries from new and existing customers every day. Of course, we welcome every new enquiry, but in order to be able to prepare a suitable quotation for a metering and mixing system, we need to analyse the task in detail. This is necessary so that the system technology can be optimally matched to the task. This is the only way to ensure that the greatest possible benefit is achieved. But what exactly is to be achieved? Why is the investment in a system planned? For capacity reasons? Can the required quality no longer be achieved manually?

In order to configure a system properly, all the necessary information must be compiled in full: Task, process parameters, environment, commercial aspects, etc. In particular, the system must of course be matched to the material to be processed. Easier said than done, because two worlds collide here. The customer knows his process and the requirements. As a plant and machine manufacturer, we are familiar with our metering and mixing technology and can design it for the respective material and process. But how do you get the two to work optimally together? Nothing is worse than talking past each other when determining requirements. Therefore, all important parameters must be clarified during the preparation phase. The more detailed and comprehensive the influencing factors are known, the more successfully the system can work later on.


The general structure of a metering and mixing system

The system technology essentially consists of the material supply, the dosing system, the application unit (also known as the mixing head) and the system control. The actual dosing system is selected depending on the adhesive, sealant, etc. to be processed. Gear systems, volumetric or piston dosing systems and progressive cavity pumps are available in various sizes.

If the material to be processed consists of two or more components, it is essential to prepare them using a mixing system. The choice of mixing system essentially depends on the material viscosity, the mixing ratio to be achieved and the required dosing quantity/time unit. Other parameters such as mixing quality or processing time must also be taken into account. In modern dosing and mixing systems, all relevant process data is also monitored using gear wheel measuring cells, screw spindle encoders, Coriolis measuring systems, etc.

With this equipment, the system technology is able to detect process deviations and readjust automatically. The wear of components can also be partially corrected and the system can automatically report any necessary maintenance.

To ensure that a dosing and mixing system can be optimally designed, we follow the man-machine-material principle in practice. All relevant influencing factors in the respective areas are determined, scrutinized and taken into account during planning. People, with all their strengths and weaknesses, are one of the biggest challenges here. This is because incomplete specialist knowledge, different perspectives and motivations, particularly among plant operators, can have unforeseeable consequences in production in later years. 

In order to avoid design errors when designing the dosing and mixing system, we provide an overview of possible risks and influencing factors during subsequent production and give suggestions on how these can be prevented at the design stage. 

When planning a system, it is therefore important to analyze a large number of influencing factors in advance. It is worth the effort, as this is the only way to prevent costly errors and ensure that the new technology to be installed delivers the greatest possible benefit.

Possible consequences of design errors

  • Risk of production errors or quality fluctuations in the components to be manufactured 
  • Increased system wear 
  • Additional maintenance and servicing costs 
  • Lack of added value: the systems do not offer sufficient added value or do not amortize themselves

1 Possible influence factors by employees | Preventive measures

Risk of material mix-up at the system System captures material using a barcode scanner
Material contamination during container change System has a filtration system in the material flow
Incomplete expertise Hiring a bonding specialist in the company

Regular training or education of operators

Written instructions in the local language
Health hazards when loading materials into the system Exhaust systems with air control

Training courses and instructions on material handling
Manipulation of system technology Parameter password protection
“Creativity” of operators Convey expertise, e.g., bonding practitioner course

Regular inspection of workplaces and work steps
Handling of substrates to be bonded Do not touch prepared surfaces to avoid transferring skin oils
Ergonomic design of workplaces, health,
performance, endurance, concentration, and motivation of employees

Handling errors when using application guns
Optimal material supply and removal

Adequate ventilation

Good lighting conditions

Provide tools and protective equipment (gloves, safety glasses)

Ergonomic design of application guns

2 Possible influence factors in material processing | Preventive measures

Material selection Close coordination with the material manufacturer: Check material for the specific application

Determine safety classes for bonding

Processing time of the material, e.g., under fluctuating ambient temperatures
Installation site Dirt and dust: Bonding surfaces must be clean, grease-free, and dust-free
Ambient temperatures Optimal temperature range is usually between 15 and 25 degrees

Ensure consistent process and material temperatures

Maintain consistent component temperatures (very cold or very warm components can alter the material's reaction speed)
Fillers Install material circulation system (possibly controlled)

Choose the correct supply and dosing pumps

Process material with a batch mixer

Regularly check material density
Moisture Follow proper handling of materials when loading into the system

3 Possible influencing factors in the system design | Preventive measures

Material What are the general requirements for the process and quality, in particular dosing accuracy?

In this context, the appropriate dosing system must be selected: Gear system, volumetric or piston dosing system or progressive cavity pump?
Dosing system Fillers of the material?

Viscosity?

Mixing ratios?

Pressure sensitivity of the material?

Moisture sensitivity?

Dosing quantities? (small/large)

Continuous process data recording?

Service life/maintenance intensity?
Application device (mixing system) How should the application be realised: manual or automated?

What dosing quantities or shot sizes should be realised?

Weight and size of the application device?

Can suitable ergonomics/handling be realised?

Defined regeneration position?

Mixer selection: static, static-dynamic or dynamic?
Media lines cross-sections and length?

Is the design cooled or heated?

Is moisture-sensitive material being processed?

Bending radii for hose lines?
Container size Design according to the expected material consumption/time unit

Must materials be prepared before processing (degassing, stirring); must this be taken into account in the design so that there are no unnecessary interruptions to production?

Handling of container sizes? (weight, hazardous goods class, storage)
Uninterrupted operation Provide for redundant operation (for uninterrupted operation)
Distance material supply to application device, power losses Decentralised installation of system technology

Use of temperature-controlled media lines

Set up dosing system in the immediate vicinity of the application
Process deviations Monitoring of all critical process parameters

Cyclical monitoring of dosing (manual/automatic)

Automatic process data correction
Securing the process data Design of the dosing technology with gear wheel measuring cells, screw spindle encoders or Coriolis measuring systems?

Transmission to an external centre?
Master/slave function interfaces

Interface plan

Standard processes Interface design
Power supply What voltage is available?

Does a transformer have to be provided?
Dosing quantities Dosing quantities small/large

Required dosing capacity

Type of application (bead application, dot application, etc.)

Tolerances

Your partnership with DOPAG

  • One contact for the entire system solution
  • All applications from one provider
  • Implementation of specific requirements and automation
  • Competent support from DOPAG experts
  • A dedicated technical centre for testing and customer training
  • Close collaboration with material manufacturers
  • Decades of experience in metering and mixing technology
  • Global distribution and service in over 40 countries

Reference projects

Applications

Choose your applications:
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