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.
"Mixing plants? We've been doing it forever - as long as I can remember!"
Book your free, no-obligation personal consultation with Jürgen Opdenhoff now for mixer control.
TABLE OF CONTENTS
ADVANTAGES OF AUTOMATED MIXING PLANT CONTROL
The advantages of automated control and optimization of mixing systems:
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.
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.
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.
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.
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.
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.
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.
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.
Out often the Box
Experts in mixing and weighing - mixing systems 4.0!
We support you and deliver everything from consulting to service in the finished production - everything from a single source!
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How it works: Control and optimize mixers
Raw material handling
Recipe change
Precision in the mix
Simple granulate dosing
Dosing characteristics
Continuous vs. discontinuous dosing
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:
Continuous production
- Components are added evenly
- the mixing process runs through without pauses
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
Segregation in promotion
Damage to the granulate
Creation of angel hair and dust
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.
Typical materials
Dryblend
- (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
Lubricants
- (base fluids, base oils + additives) for the production of Lubrication of machines and wire drawing systems
Colors
- (pigments + dyes) for the production of Plaster and wall paints
Sand and gravel / refractory / dry mortar
- (lime + additives) for the production of Joint sealants
Cappuccino
- (cocoa + sugar + additives)
Baking mixes/breadcrumbs
- (flour + water + additives) for the production of Powder, bread, dough
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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