gravimetric blenders mdw series - · pdf filea complete range of gravimetric blenders...

PLASTICSTECHNOLOGIES

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Gravimetric blendersMDW Series

English

The Piovan MDW Series batch gravimetric blenders are ideally suited for application oninjection moulding machines, blow moulding machines and extruders. Slide gates, highprecision augers and micro-cell devices ensure that the various components are dosed in theset percentages.

imp MDW ing 9-10-2003 14:15 Pagina 2

A complete rangeof grav imetr ic b lenders

Piovan’s range of MDW gravimetric blenders consists of six models with capacities

from 30 to 1500 kg/h. They can dose, weigh and blend up to six materials.

The blenders are equipped with individual feed hoppers

for each dosing station (virgin, regrind, masterbatch and

additives). Low level sensors can be fitted to detect and

warn of material shortage (a standard feature for MDW 20

and MDW 70 models). Materials are transferred one by

one into the weigh pan using pneumatic slide gates,

augers or rotating micro-cells (the latter for MDW 20 only)

until the set batch weight is achieved. The batch is

transferred into the mixing chamber, mixed before it is

transferred into the processing machine throat.

Installation

MDW blenders can be installed with injection moulding machines, extruders and blow moulding machines, either floor-

standing (to feed one or more machines) or directly onto the operating machine feed throat. Vibrations caused by the

machine movements are filtered by the management software. When the blender is installed beside the processing

machine, an additional pneumatic slide gate is installed between the mixing chamber and the suction box so all

batches are thoroughly mixed.

MDW 70


MDW Ser ies

Advanced technology

The innovation of the gravimetric blender MDW 20, the smallest model in

the series, is in the rotating micro-cell dosing device, which transfers the

minimum quantity of masterbatch or other additives in the weighing

hopper. The micro-cell dosing system holds micro-quantities of material

such as masterbatch and transfers this regularly into the weigh pan,

guaranteeing outstanding precision and stability even when dosing small

quantities.

MDW 20

Other materials, such as Virgin and Regrind are transferred into the weighing

hopper using pneumatically operated slide gates. The combination of these

two dosing systems guarantees outstanding precision and repeatability of the

dosed batches. The batch weight is only 500 grams.

The stainless steel dosing hoppers are equipped with antistatic low level

material sensors. An antistatic level sensor is also installed in the mixer as a

standard feature.

Micro-cell dosing device


Configurations

For each material to be blended (virgin, regrind and/or additives) an individual feed hopper is provided. In the MDW 20 and

MDW 70 models, it is possible to fit the blender initially with a reduced number of dosing units (minimum two) and then

increase the number up to four in due time.

MDW dosers are designed and manufactured to allow quick and easy cleaning

and maintenance operations. Access to the mixer is quick and easy thanks to the

use of hinges or hand wheels to open the front panel. The mixing chamber, mixer

and weigh pan are easily removable. As an option, blenders can be equipped with

a dummy weigh pan in order to empty and collect surplus materials from the

hoppers when changing materials. In all models, it is possible to inspect the weigh

pan and the mixing chamber from the outside through a transparent window.

The MDW 20 and MDW 70 mixing chamber is cylindrical and has a conical

bottom that avoids unmixed batches and makes the units easy to clean. The

mixing chamber as well as the mixer shaft and weigh pan are made of stainless

steel.

The possibility to install slide gates, augers and rotating microcells

(the latter in the MDW 20 blender only) and to vary the number of

dosing units allows for a greater number of possible machine

configurations, adapting them to the specific requirements of each

production process. A special 8-litre capacity feed hopper is also

available for the MDW 70 blender.

MDW 20: the mixing chamber Configuration with 3 dosing units

Easy to use

MDW 250: the mixer


MDW Ser ies

Precision and accuracy

The load cell weighing system has an accuracy of 1/100th of a gram and the display will show the percentage dosed

for each material. The microprocessor control continuously corrects the actual weight of each component keeping it at the

set value. MDW dosers assure the repeatability of the quantities to be dosed.

All the MDW series blenders are equipped with microprocessor control installed in the blender frame. This can store up

to 99 recipes which can be easily recalled. The operator interface can be selected from two different keypads depending

on the specific production needs: the Maxima keypad and the mini keypad. The two keypads are interchangeable.

enter recipes with titles and comments

change a recipe while the blender is in

operation

information regarding the total material

consumption of each individual dosing

station

calibration of the load cell system

setting of mixer parameters

alarm management

three security password levels

control of material hopper level sensors

special regrind programmes

fast material change programme.

Maxima Keypad

The Maxima keyboard is a sophisticated keypad with a large display and standard RS 485 serial port, and

provides a wide range of functions:

The Maxima keypad allows easy programming of the blender. The operator presses dedicated keys to enter the

various material percentages to instantly produce the required blend, with no need for further setting, testing or

calibration.

Maxima keypad


Auto-calibration

MDW blenders are factory pre-set to allow a quick start-up. The operator simply

enters the ingredient percentages to be weighed. The microprocessor calculates

the quantity of material to be weighed for each ingredient. The operator can refer

the percentages to the batch or to either one or two virgin materials. The MDW

blenders software is equipped with a special auto-calibration algorithm for

speeding up machine start-up: a few batches are enough for stabilising dosed

quantities.

Special programmes

The unique Turbo function can be selected from the keypad and allows the throughput of the blender to be increased. The

“Turbo” function alternates between volumetric and gravimetric operating modes on each dosing station. The time required

to prepare the batch becomes shorter, increasing the blender output.

The microprocessor control also provides two special Regrind programmes for

the management of regrind materials. If there is a lack of regrind material, the

programme automatically increases the weight of the other ingredients keeping the

ratio and batch weight unchanged. If there is an excess of regrind material, the

control automatically increases the weight of the regrind and adjusts the weight of

the other ingredients without changing the pre-set proportions and helps use up

excess regrind.

The mini keypad is fitted with RS 485 serial port and allows for the management of

the basic parameters. By installing the Win Dosing System management software,

it is possible to use a mini keypad instead of the Maxima keypad as the local

operator interface.

Mini keypad with RS 485 port

MDW 250

MDW 1000


MDW Ser ies

Win Dosing System,the P iovan software

for grav imetr ic b lenders

The Win Dosing System is the software that Piovan has

specifically developed to control and manage the Piovan MDW

Series gravimetric blenders. Win Dosing is a simple and

powerful tool which can manage up to 16 gravimetric blenders

from the one PC station.

The Win Dosing System is configured according to the number of blenders installed in the plant. In the case of blenders

installed at a later stage, it is only necessary to enter a new access code and to configure each additional blender. The

various blenders in the plant are interconnected via a serial line (RS 485) that allows for communication with the PC.

Monitoring and on line control of the blenders

operating status (ON, OFF, dosing, stand-by, alarm, off-line)

recipe reading and allocation including compatibility check with

each blender

modification of a recipe while in progress

reading of working percentages per batch

total and partial material consumption indicator in kg for each dosing

hopper

START and STOP of the dosing unit

alarm RESET

disconnection and automatic reconnection of the dosing unit from the

software. This function allows for setting and maintenance operations.

Windosing


Win Dosing allows for checking the quantity of material processed by each hopper of the blender/s and of the

machine’s overall consumption, after specifying the reference time lapse. It is possible to identify the consumption

of each work shift within the set time lapse.

Recipe and consumption management

The Recipe Manager is a specific database of recipes with a possible

link to the Material Database. The data identifying a recipe is:

name of the recipe

date of creation and date of the last modification made

name of the mix

mixer revolution time

number of Turbo cycles

working percentages of the dosing hoppers

material processed in each hopper

first and second regrind levels

working modes for each dosing hopper in the event of a material

shortage.

Dedicated Databases

The Material Database stores information on the materials

processed. It is possible to allot a purchase price to each

material, in order to use it in the advanced functions to calculate

the cost of each production lot.

The Provider Database allows for classifying, in a simple way,

the information on plastic materials providers.

The Win Dosing System software also includes a Plant Diary,

in which all the events concerning the dosing system are

recorded (including operations and alarms). Events can be

sorted by time, type or unit.

By clicking on the specific alarm, it is possible to enter the Alarm Database and to receive suggestions on possible

causes and remedies. It is possible to send a copy of the relevant records from the Plant Diary as a text file to Piovan after-

sales service for a subsequent diagnosis of the problems encountered. To access the software it is necessary to digit an

access password: each entitled user is registered in the User Database, where all the operations he is allowed to carry

out are listed.


MDW Ser ies

Advanced funct ions

This optional service allows the list of production runs ready to be processed to be entered and, at the same time, to monitor

the production runs in progress. The creation of a new production run involves the definition of the mode at run stop either by

production, according to the quantity to be produced, or by time (date of job end) as well as the choice of waste monitoring*.

The Production run management optional function includes a database

that collects the following data on each job:

name of the job

time it started and time it ended

blender name

name of the mix produced

name of the recipe being processed

name of the materials of all stations

name of the material providers

set working percentages of each station

real working percentages

material consumption for the single hoppers and for the overall job

waste produced by each hopper and totally, if the waste monitoring

function is selected (cf. *)

cost of the material for each hopper and of the overall production

run.

Consumption survey

For each run, it is possible to print a production report, pie charts and

histograms on the produced mix (quality production certification) and

on the waste produced vs. the valid production (production efficiency),

if the corresponding function was selected (*).

It is also possible to enter the database by stating the inquiry time lapse

with the possibility of an advanced search using research filters (recipe,

material used, blender…).

One of the advantages of the production run management is that the

operator can monitor the consumption and this helps monitor stock

definition and reordering of materials. It is a valuable simplification for

production programming.

Production management


Other optional services

The Alarms display management service is available as an optional feature and it manages the visualisation of

alarms relating to the dosing plant via a large rolling display. The display can be installed in a visible spot in the

factory from where it will be possible to constantly monitor any alarm signal. Messages, which are easy to

program, can be customised by the user. On request, the Net management service guarantees the possibility of

having two or more Client stations connected to the server.

MDW 20 MDW 70 MDW 250 MDW 500 MDW 1000 MDW 1500

Batch weight* kg 0,5 1,1 2 4 9 18

Auger motor power kW 0,015 0,18 0,18 0,18 0,18Mixer motor power ** kW 0,11 0,18 0,3 0,3

*** 0,65 0,9Capacity of the mixing chamber dm3 2,5 7 12 20 40 70

Capacity of the auger hoppers dm3 18 (8) 20 20 30 30

Capacity of the slide gate hoppers dm3 6 18 (8) 40 60 75 100

Nominal capacity kg/h 30 80 250 500 1000 1500Installed power ** kW 0,12 0,35 0,8 0,8

*** 1,2 1,3Compressed air pressure bar 6 - 8 6 - 8 6 - 8 6 - 8 6 - 8 6 - 8

Max compressed air consumption Nl/h 50 160 160 160 200 200

Weight kg 50 150 210 240 340 370

* Nominal values** 230 V / 50-60 Hz single-phase*** 400 V / 50 Hz - 380 V / 60 Hz 3-phase

1557

807

1005

/ 1

140

MDW 70MDW 20

MDW 2

777840

1020

740

577572

715


MDW Ser ies

Model Dosing VersionsStations Slide Gates Augers

MDW 20* 4 max 4

MDW 70 4 max 4 max 2





250 / 500 MDW 1000 / 1500

850

1175

/ 1

400

1900 / 1930

1115

1420

/ 1

590

1115

1630

/ 1

890

* Also available with micro-cell dosing stations


PIOVAN S.p.A.Tel. +39 041 57.99.111Fax +39 041 [email protected]

PIOVAN GmbHTel. +49 89 32.94.57.0Fax +49 89 [email protected]

PIOVAN CANADA Ltd.Tel. +1 905 671.97.00Fax +1 905 [email protected]

PIOVAN do BRASIL LtdaTel. +55 11 3693.9500Fax +55 11 [email protected]

PIOVAN ASIA Pte LtdTel. +65 6 87.45.930Fax +65 6 [email protected]

PIOVAN HONG KONG LtdTel. +852 23.68.87.28Fax +852 [email protected]

1003

- 9

9105

83 -

Mod

ifica

tion

Res

erve

d -

Pio

van

S.p

.A.


gravimetric blenders mdw series - · pdf filea complete range of gravimetric blenders...

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