24092 - Automated liquid production line

The machine is designed for the simultaneous preparation of three water-based mixtures containing liquid and powdered additives, in accordance with the recipes selected by the operator.

 

Intended use of the equipment

  • automated dispensing of mixture ingredients from IBC containers, with the option of manually adding powdery or liquid ingredients via a hopper;
  • mixing of all ingredients in 3 independent tanks;
  • optional use of one tank for a pre-mixed pumped mixture, followed by transfer of the finished product to two tanks;
  • precise guidance of the operator through all stages of the production process;
  • protection of the process against the dosing of incorrect additives;
  • automatic unloading of mixtures into IBC containers.

 

Description of operation

Preparation of the mash

  • automatic dispensing of ingredients from IBC tanks in the quantities specified in the recipe;
  • mixing the contents of the tank for a predetermined time, with the option to continue if the ingredients are not sufficiently combined;
  • depending on the settings, the dosing of the additive is confirmed each time by scanning the ingredient’s Data Matrix code and/or pressing the dosing confirmation button.

Preparation of the finished product

  • automatic withdrawal of the appropriate quantity of hot or cold water from the system;
  • manual addition of powdered and liquid additives via the feed hopper, preceded by scanning the substance’s code and confirmed by a button on the control panel;
  • automatic withdrawal of the previously prepared mash;
  • automatic transfer of the finished mixture to an IBC container.

Equipment design

MIXING TANKS

The unit is equipped with 3 HDPE tanks with a working capacity of 1.5 m³. One of the tanks can be used to prepare a preliminary mixture, which is then used to produce the finished product in the other two tanks.

 

FEED HOPPERS

Each tank is equipped with a feed hopper featuring a flap locked by an electromagnetic lock and controlled by an inductive sensor. This solution eliminates operator errors by requiring the correct additive code to be scanned (to unlock the lid) and the completion of dosing to be confirmed by pressing a button (to lock the lid).

 

INGREDIENT TRANSFER SYSTEM

The system consists of a manifold allowing the connection of 4 IBC tanks containing ingredients, a pump and an automatic valve, which enables the ingredients to be drawn off and transported to the pre-mix tank.

 

OPERATOR GUIDANCE SYSTEM

Each tank has its own operator panel, which displays the successive steps in the mixture preparation process. Some additives are dispensed automatically. Other additives, which are dispensed manually, require the code assigned to the relevant ingredient to be scanned beforehand. Scanning the code for the additive corresponding to the current step in the recipe releases the lock on the hopper lid and allows the substance to be dosed into the mixture in the tank. The completion of the additive dosing is confirmed each time by a button on the control panel, allowing the machine to proceed to the next step in the recipe.

 

CONSTRUCTION

The structure is made of steel profiles, featuring an upper platform for operating the tanks and a lower platform allowing unrestricted service access to every part of the machine. The access stairs and platforms are designed to ensure maximum working comfort and freedom of movement for operators.

 

ADDITIVE STORAGE AREA

To ensure maximum ease of use, a storage area for bulk additives has been designed next to the process platform. Additives are transported to the platform using a forklift truck after the access gates have been unlocked and opened.

 

SPACE FOR IBC CONTAINERS

There is space for 6 IBC containers within the machine. 4 containers hold process additives, whilst the remaining 2 are used to unload the finished product from the tanks.

 

DRIP TRAYS

The machine area is protected against liquid leakage by drip trays located beneath the process tanks.

 

CLEANING CONNECTIONS

The system includes water connection points for a pressure washer and inspection ports in the tanks designed to accommodate a cleaning head. Additionally, in accordance with the customer’s specifications, it is possible to connect a water source containing a cleaning agent to the system, thereby enabling the flushing of the pumps and the process system.

 

Benefits for the customer / user

  • Simplification of the compound production process – all necessary equipment and ingredients gathered in one place;
  • Automation of the ingredient dosing and mixing process;
  • Elimination of the possibility of errors thanks to an operator guidance system and the use of access control for the compound being produced;
  • flexible recipe design and freedom in the choice of ingredients;
  • safe and ergonomic design for operators and maintenance staff.
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