For packaging liquid chemicals, generally speaking there are no off-the-shelf process equipment solutions. Customizations for safety, corrosion resistance, product integrity and material compatibility are a common areas of focus. In the coatings industry, highly specialized products made with proprietary formulations are no exception.
In a rapidly expanding industry, with exceptional growth in international markets, a big challenge for one manufacturer was finding a way to manage multiple container size changes for every product batch and maximizing the yield of product with multiple batch changes per shift of operation. The solution: Ideal-Pak®’s AE4-CAM with patented DFS® Direct Fill System gravity product delivery.
In any liquid filling process, maintaining consistent pressure at the dispense point is critical to clean, accurate fill results. With DFS® pressure is as consistent as gravity. Using a non-contact ultrasonic level sensor, variation of product volume in the tank is minimal allowing the outflow of material to remain constant even as individual containers reach their target weight and product delivery paths are closed. By also integrating Ideal-Pak® vented cone nozzles directly into the tank, product delivery is exceptionally clean reducing clean-up and eliminating product spray that otherwise can foul sensors and jam cylinders.
Product yield also benefits from DFS®. On a four head filling system, 7 ball valves and 7’ of process piping are eliminated from the delivery circuit. The smooth stainless steel surface is easily wiped down allowing the few pints of remaining material to be dispensed into the last containers. For this manufacturer, that still isn’t good enough. Add interior spray balls and sealed tank covers and product delivery flushing is cut in half using 50% less cleaning material. With these added features conversion between pigmented and non-pigmented products is confidently executed without concern for cross-contamination.
To have the most positive impact on labor content, automating lid placement and container closing is a requirement. Still, these features have to be quickly adjusted between different size containers without the added cost of application-specific tooling. With the Ideal-Pak® LPA-0000 lid placer and 2340-HR Roller closing station, the adjustments are simple and it is the packaging materials that act as the “adjustment gage.” What could be simpler than that?
Finally, a custom-designed 180° powered conveyor and low-cost gravity conveyor extension are applied to reduce the process footprint and create a compact work cell easily managed by a single operator. With qualified labor shortages starting to impact the workforce and labor costs on the increase, such investments are hugely beneficial to keep labor cost from becoming the top cost contributor to your products.
Let’s talk about engineering a solution to your process challenges today! Call (800) 383-1128, email email@example.com, or visit our website at ideal-pak.com and fill out the Request Information Form on the Contact Us Page.AE4-CAM, Liquid Filling, Liquid Filling Machine