Raw Material Formulation Machine

Raw Material Formulation Machine

Key Features of the Raw Material Formulation Machine

High-Accuracy Weighing and Consistent Batching

• Gravimetric batching with high-resolution load cells ensures repeatable accuracy down to sub-gram levels for critical additives.
• Servo-driven micro screw and vibratory feeders stabilize flow for cohesive and low bulk density materials.
• Adaptive control algorithms with auto-tare and overshoot suppression improve yield and reduce additive waste.

Broad Material Compatibility and Clean Handling

• Handles PVC stabilizers, lubricants, CaCO3, TiO2, flame retardants, impact modifiers, colorants, carbon black, and moisture-sensitive resins.
• Anti-bridging hoppers, agitation, and fluidizing pads prevent rat-holing and segregation during dosing.
• Enclosed transfer with dust extraction ports keeps the environment clean and avoids cross-contamination.

Smart Controls, Recipe Management, and Traceability

• PLC + HMI with multilingual UI, recipe library, digitized SOPs, alarms, and user permissions.
• MES/ERP connectivity via OPC UA/Modbus TCP enables end-to-end batch traceability and electronic batch records.
• Barcode/QR ingredient verification and batch report export (CSV/PDF) minimize human error and speed audits.

Efficient, Modular, and Low-Maintenance Design

• Tool-free quick-release feeder screws and tubes for rapid color grade changeover.
• Stainless-steel contact parts (304/316L) with smooth welds for easy cleaning and hygiene.
• Predictive maintenance, drift diagnostics, and auto-calibration routines maximize uptime and reduce service cost.

Applications and Industries

Plastics, PVC, and Masterbatch

• Precise micro-additive dosing for rigid/flexible PVC, profiles, pipes, SPC substrates, sheets, masterbatch concentrates, and WPC modifiers.
• Compatible with conical twin-screw and single-screw extrusion lines, injection molding, and compounding extruders.

Building and Construction

• Accurate formulation for PVC panels, window profiles, cable ducts, pipe fittings, roofing membranes, and decorative boards.

Furniture and Interior

• Stable color and gloss management for furniture panels, edge banding, decorative films, and laminates.

Automotive and Electronics

• Controlled addition of flame retardants, UV stabilizers, antistatics, and impact modifiers for interior trims, housings, and connectors.

Rubber, Coatings, and Chemicals

• Micro-ingredient formulation for rubber compounding, ink and coating additives, catalysts, adhesives, and lab-to-pilot lines.

Technical Specifications

Performance and Capacity

• Dosing accuracy: typically ±0.2–0.5 g per component (material dependent).
• Feeder throughput: approximately 0.05–30 kg/h per micro-feeder; system throughput up to 100–800 kg/h depending on configuration.
• Modes: batch weighing, continuous gravimetric loss-in-weight, and hybrid recipes for multi-component lines.

Mechanical and Configuration

• Feeder types: micro screw, twin micro screw, and vibratory tray; interchangeable screws for different flow behaviors.
• Hopper volumes: 5–80 L with level sensors; anti-bridging devices and dehumidified hopper options.
• Construction: 304/316L stainless-steel contact parts; food/pharma-grade seals; viewing windows and LED bin indicators.

Controls, Connectivity, and Safety

• PLC/HMI with audit trail, recipe versioning, and real-time KPIs (accuracy, OEE, batch cycle time).
• Connectivity: Ethernet, OPC UA, Modbus TCP; printer/label export; API hooks for MES/ERP and LIMS.
• Safety: interlocked doors, overload protection, dust collection interface, ATEX options for explosive dust environments.

Energy and Utilities

• Power: 1.5–8 kW depending on number of stations, agitators, and conveying.
• Compressed air: 0.4–0.6 MPa for pneumatic gates, purging, and fluidization.
• Energy-saving standby and smart wake-up to lower idle consumption and peak load.

Note: Specifications vary with material characteristics, number of feeders, and target throughput. Custom multi-station configurations and scale-up paths are available.

Customer Case

User Recognition and Market Performance

Customer Feedback

• Manufacturers report 30–50% reduction in batch variability and 8–12% additive savings due to precise micro-dosing.
• Operators highlight the intuitive HMI, quick changeovers, and clean, dust-free operation.
• Quality teams value complete traceability, faster audits, and compliance with ISO/GMP documentation.

Representative Case Studies

• PVC profile plant: reduced start-up scrap by 18% and stabilized color ΔE by 40% using barcode-verified recipes and gravimetric dosing.
• Masterbatch producer: cut off-spec lots by 25% after implementing electronic batch records and ingredient verification.
• Automotive supplier: achieved consistent FR performance and antistatic properties across three shifts with sub-gram control.

Market Competitiveness

• Strong ROI via lower additive waste, fewer quality claims, higher OEE, and quicker product changeovers.
• Modular expansion and Industry 4.0 connectivity future-proof the investment and support data-driven optimization.