Fully automated production plant for the manufacture of adhesives and sealants
The key processes at a glance
"The new production line not only increases the production capacity, but also delivers better, even more consistent product quality. At the same time, it reduces waste and emissions: This is a building block of our concept for more sustainability, which ultimately also benefits customers and employees."
(On the official opening of the new production line to PNP.de)
Johann Hafner/ Managing Director Otto Chemie
Fitech offers "best-in-class" mixing technology for medium- to high-viscosity sealants and adhesives. In addition, the company follows a systematic and planned approach to the development and implementation of process engineering. The end result is high-quality, tailor-made and safe machines and systems in Swiss quality. fitech has many years of experience and comprehensive know-how in plant engineering. From the initial idea to commissioning, fitech offers a wide range of engineering and service competencies, taking into account all applicable standards, regulations and safety requirements.
Fumed silica is conveyed fully automatically from the tank wagon to the silos. The downstream feed hoppers are automatically fed from the silos.
All powdered raw materials are dosed with a dosing accuracy of +/-1%. The dosed quantity is reported to the control system and stored in the batch report
High-viscosity polymers and plasticizers are pumped fully automatically from tank trucks into WHG-compliant storage tanks. Additives from IBCs and drums are stored in high-bay warehouses with WHG vats and dry air blanketing. The downstream intermediate tanks ensure trouble-free IBC and drum exchange during ongoing production.
The dosing accuracy from the tank system into the vacuum mixer is +/-1%, from IBCs and drums +/-0.5%. The dosed quantities are reported to the control system and stored in the batch log
The heart of the plant is the vacuum mixer for compounding, which decisively determines the quality of the product. Thanks to an innovative mixing technology, the mixing process can be completely automated and operated for several weeks without cleaning. All raw materials are precisely metered into the mixer from a self-contained system. When the mix is discharged under vacuum, the mixer train cleans the container wall and helps to convey the mix into the pump shaft.
QUALITY CONTROL AND QUALITY ASSURANCE UNDER VACUUM
Quality control is carried out under vacuum. Samples are drawn from the mixer into cartridges. The request for sample removal can be automated via the DCS. The samples are analyzed in the laboratory and released at the control if the quality is satisfactory. Subsequently, the mixer is emptied with the aid of the discharge pump. For quality assurance, the finished product is filtered between the mixer and the buffer press.
SECURE INTERMEDIATE STORAGE
The hydraulic buffer presses serve as airtight and sorted intermediate storage after mixing (batch process) and before filling/packaging (continuous process).
The useful volume of the buffer presses is 8m3, which corresponds to 5-6 batches in the mixer. The discharge pump under the mixer conveys the product into the buffer presses, which can be filled and emptied simultaneously. With a hydraulically operated follower plate, the material is pressed out and conveyed to the filling line by means of a downstream pump.
CONTROL SYSTEM, PLANT CONTROL AND DIGITALIZATION
The production control system consists of the plant management level (MES), the process control level (SCADA), the control level (PLC) and the field level.
With the exception of the electrical field devices of the outdoor silos, the entire compound production plant is controlled by a central switchgear. The field devices are connected to the switchgear via a BUS signal.
The plant is operated either via the DCS at the control station, directly at the mixer via a touch screen or a mobile industrial tablet. The powder and liquid charge can be operated on site. In addition, pushbutton control boxes have been installed for service functions.
Digital data acquisition enables the optimization of process steps and key factors, as well as the establishment of a variable sequence structure in batch production.