Control and optimize dosing and mixing systems

Many products are now offered in different variations. Where there used to be one muesli bar, there are now 10. Flour is available in "wheat", "spelt" and "gluten-free". Even in the packaging sector, each type of shampoo not only has a different label - the entire bottle is individually colored.

A variety of products that can no longer be sensibly mapped using manual mixing processes - especially in the food sector, where the mixing process must be clearly documented and verifiable months later in case of doubt.

The solution: an automated, recipe-based mixing control system.

Mr. Opdenhoff: Contact person for mixer systems

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The advantages of automated control and optimization of mixing systems:

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Making life easier for the system operator

The operator can set the system based on the current recipe, there are fewer sources of error and the system status can be seen at a glance via a dashboard.

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Robust documentation

The production process is clearly documented thanks to the automated dosing and mixing control. In addition to the obligatory retention samples, this documentation provides a high level of security in the event of subsequent product problems. If required, the document data can be archived in an audit-proof manner during the production process in order to be prepared for inspections by the authorities, for example.

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Clear production status - 360° view of the system

The complete system status is visible to the machine operator at a glance - problems can be quickly identified and rectified via process visualization. The mixing process can be intuitively controlled, monitored and optimized using process data.

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Precise control of the dosing and mixing process

The various recipes for the individual products are stored in the recipe database. The mixing control system retrieves the relevant recipe and automatically adds the raw materials in the correct mixing ratio.

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Allocability of raw material batches

The automated mixing process also documents the raw material batch numbers used and their allocation to the finished product. Identification takes place via a QR code (LOT number). If a particular batch is recalled by the manufacturer, for example, the end product made from it can be easily assigned.

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Compensation of environmental conditions

The dosing of bulk materials has many sources of error. These include vibrations caused by passing forklifts as well as moisture, which can lead to clumping in the case of hygroscopic raw materials, or static charge, which causes material to build up on the discharge unit. An automated control system can measure these environmental conditions and incorporate them into the dosing and mixing process.

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Filling levels and refilling processes

If a hopper is completely full, a dosing unit requires more force to transport the same amount of material. If the hopper is being refilled from the silo, practically no meaningful measurement is possible - however, the automated mixing control recognizes this and simply maintains the current target values and starts a new measurement as soon as the process is complete.

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Error avoidance

We are all human, and experience has shown that concentration is no longer as high in the seventh hour of the night shift. Automating the dosing and mixing control minimizes the human factor and ensures that sugar is still added at four in the morning and not salt.

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Experts in mixing and weighing - mixing systems 4.0!

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Mr. Brunetti: Contact person for dosing systems

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How it works: Control and optimize mixers

Raw material handling

The raw materials must be fed and mixed in the production process. The individual raw materials often have to be homogenized in order to guarantee consistent product quality.

Recipe change

Simple recipe changes during production based on a recipe database make it possible to react flexibly to changing production requirements. Even employees with little experience can react confidently to recipe changes thanks to automation.

Precision in the mix

Automation ensures high-precision quantity ratios. Exact weighing ensures verifiable compliance with recipes. Compliance with standard curves is also supported.

Simple granulate dosing

For most mixing processes, volumetric dosing of the components is completely sufficient. For critical mixing processes, gravimetric weighing can also be used as a safety net.

Dosing characteristics

An automatically determined dosing characteristic curve in the range of the setpoint increases the stability of the dosing by reducing the reaction time to fluctuations in the overall system.

Continuous vs. discontinuous dosing

The OPDPRO.CARE control system for mixing systems can map both continuous and discontinuous dosing. Continuous dosing in particular requires constant monitoring of the component flows, as it is not possible to carry out gravimetric monitoring as is the case with batch weighing.

Mixing control for asphalt mixing plants

We also offer central control systems for asphalt mixing plants that produce asphalt mixes. Here, binders are thermally mixed with mineral stones and other fillers.

The following are distinguished two different production processes differentiated:

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Continuous production

  • Components are added evenly
  • the mixing process runs through without pauses
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Discontinuous production

  • Components are added in heaps
  • Changes can be implemented flexibly at any time

Challenges in dosing: what can go wrong

Segregation during storage
Statistically speaking, small grain sizes of bulk goods sink downwards, while large grain sizes rise upwards. If a raw material is not used for a longer period of time, for example if it is stored in a warehouse or silo, it can segregate during storage. In automated mixing systems, an additional homogenization stage can be interposed based on the recipe. This ensures consistent product quality despite longer storage periods.
Segregation in promotion
The same problem occurs with vacuum conveying, for example. Small grain sizes are transported faster than large ones. A mixing material that is cleanly homogeneous in the store is therefore segregated during transport and must be homogenized again before being fed into the extruder.
Damage to the granulate
Some raw materials are very sensitive to damage during transportation. In this case, it may make sense to convey the material at a significantly lower speed than for robust materials. Thanks to the integrated system control, each raw material can be assigned a conveying speed, for example, so that materials can be transported gently.
Creation of angel hair and dust
When conveying plastic granulate, so-called angel hair is often produced: hair-thin threads of plastic that lead to inhomogeneous production. The formation of dust is also problematic: it is either material particles that are created during conveying (and can also come from the conveying pipes) or they were already present on delivery.

Angel hair can be easily controlled by lowering the material temperature. A cooling parameter can therefore be stored in the material recipe, which is switched on automatically. Reducing the conveying speed is the best way to prevent dust formation. The mixer optimization can store these parameters.

The challenges of optimizing mixing plants

Typical materials

Granulate cups for mixing system controls
Controlling color pigments with mixing systems


  • (PVC + additives) Intermediate product for the production of Window profiles

Liquid plastics

  • (lime + additives + base materials) for the production of liquid seals

Rubber compounds

  • (carbon black, oil + additives) for the production of Vibration dampers, tires and tubes


  • (base fluids, base oils + additives) for the production of Lubrication of machines and wire drawing systems


  • (pigments + dyes) for the production of Plaster and wall paints

Sand and gravel / refractory / dry mortar

  • (lime + additives) for the production of Joint sealants


  • (cocoa + sugar + additives)

Baking mixes/breadcrumbs

  • (flour + water + additives) for the production of Powder, bread, dough
Control mixing systems for food

FAQ about controlling and optimizing dosing systems and mixing systems

What is a mixer control?

A mixer controller is an electronic device that is used to mix multiple input signals and generate a single output signal. A mixer controller can be used in various applications, such as in the chemical industry, the food industry or waste water treatment.

How does an automated mixing plant control system work?

The mixer control system consists of various components, such as sensors, controllers and actuators. The sensors measure the properties of the input signals, such as the flow rate, temperature or concentration. The controllers process this information and control the actuators to optimize the mixing of the input signals.

How does an automated mixing plant control system work?

The mixer control system consists of various components, such as sensors, controllers and actuators. The sensors measure the properties of the input signals, such as the flow rate, temperature or concentration. The controllers process this information and control the actuators to optimize the mixing of the input signals.

How is a mixer control system installed and maintained?

The installation of mixer control systems requires careful planning and integration into the existing system. The maintenance of a mixer control system includes regular inspections, calibrations and cleaning to ensure optimum performance and reliability. In doing so, we adhere to the manufacturer's instructions and the applicable safety regulations.

Where are mixer controls used?

Mixer control systems are used in a wide range of applications, from the food industry to cosmetics and the asphalt mixing industry.

Are there different production processes for mixer control?

Yes, a distinction is made between two different production processes. On the one hand, there is continuous production, where the components are added evenly and without pauses. Secondly, there is discontinuous production, where the components are added in batches. If changes need to be made, these can be implemented flexibly at any time.

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