Description

Precision and Flexibility for Demanding Chemical Formulations

Achieving consistent fill volumes with viscous, non-Newtonian fluids like adhesives and construction compounds is a critical challenge that directly impacts profitability and customer satisfaction. The LBC-1000 with a dedicated product flow meter addresses this challenge head-on. This semi-automatic system is engineered for operations where production flexibility, precise batch control, and operator oversight are paramount. The flow meter provides real-time feedback and control, compensating for variations in product viscosity and pump performance to deliver unparalleled dosing accuracy. This makes it an indispensable tool for manufacturers of high-value adhesives or products where precise ratio compliance is essential. The line’s ability to handle both plastic and metal containers with simple changeovers further enhances its versatility for facilities packaging diverse product lines or serving multiple market segments.

Core System Components & Operational Workflow

1. Operator Loading Station & Powered Roller Conveyor: An operator places empty plastic buckets or metal cans onto the start of the powered roller conveyor (role gang). The conveyor then indexes the container into the filling zone.

2. Twin-Nozzle Dosing Module with Precision Flow Meter: The core technological component. This module features two filling nozzles served by a positive displacement pump. The in-line product flow meter (mass flow or coriolis type) continuously measures the exact volume or mass of product dispensed. The PLC uses this data to achieve a precise cut-off, ensuring fill accuracy within tight tolerances, crucial for expensive raw materials.

3. Press-On Capping Module with Upper Pressure Conveyor: After filling, the container is conveyed to the capping station. Here, an operator or automated feeder places a lid (snap-on plastic or press-fit metal) onto the container. A synchronized upper pressure conveyor applies controlled downward force to seat the lid securely, creating a uniform, leak-resistant seal.

4. Unified Control Panel: Houses the PLC, flow meter display, and HMI. Allows the operator to set and monitor fill volumes, conveyor speed, and view totalized batch counts from the flow meter data.

Detailed Technical Specifications & Build Quality

• Automation Level: Semi-Automatic (operator loads containers/lids; automated filling and capping).

• Filling Technology: Twin-nozzle positive displacement pump (piston, gear, or diaphragm) with integral product flow meter for closed-loop control.

• Filling Accuracy: High precision, typically ±0.25% to ±0.5% of set volume, enabled by the flow meter feedback.

• Filling Volume Range: Adaptable from 500ml to 20 liters or more, depending on container and pump setup.

• Container Compatibility: Plastic pails (HDPE/PP) and metal cans (tinplate/aluminum).

• Capping Technology: Mechanical press-on seaming/capping via an upper pressure conveyor.

• Throughput: Optimized for controlled batch production; speed depends on operator pace and fill volume.

• Construction: Durable frame with powder-coated finish; product-contact wetted parts in stainless steel or chemically resistant materials.

• Control & Monitoring: PLC control with HMI. Flow meter provides key data: instant fill rate, total volume per container, and cumulative batch totals.

Target Applications & Product Suitability

This precision-fill line is ideal for industries where accurate dosing is a critical quality parameter:

• Construction Adhesives & Sealants: Polyurethane-based adhesives, silicone sealants, epoxy resins, MS polymer hybrids, and ceramic tile adhesives.

• Specialty Chemicals & Coatings: Two-part compounds, precision potting materials, niche lubricants, and high-value industrial coatings.

• General Industrial Packaging: Batch production of cleaning concentrates, degreasers, and maintenance products where inventory control via precise filling is required.

Key Advantages of Flow Meter Integration

1. Unmatched Fill Accuracy and Repeatability: The flow meter provides direct measurement and control, eliminating inaccuracies from pump wear, viscosity changes, or air entrapment, guaranteeing every container meets spec.

2. Enhanced Process Control and Documentation: Real-time and totalized flow data allows for precise batch tracking, simplifies inventory reconciliation, and provides verifiable data for quality assurance protocols.

3. Reduced Product Giveaway and Cost Savings: By minimizing overfill, the system directly saves expensive raw material, improving the bottom line, especially for high-value chemicals.

4. Operational Flexibility and Ease of Use: The semi-automatic design is easier to set up and operate than a full line, requiring less training while still providing a high degree of automation for the core filling function.

5. Superior ROI for Batch Production: Offers the precision of high-end equipment at a cost-effective entry point, delivering a fast return on investment for manufacturers not requiring ultra-high-speed continuous operation.

📜 Schedule virtual airflow visualization test.

💡 Mention your: Target market (EU/US/Global South), Active ingredient, Required throughput.

🔬 Schedule virtual factory acceptance test with our engineers.

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