gravimetric blenders mdw series - · pdf filea complete range of gravimetric blenders...
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PLASTICSTECHNOLOGIES
1003
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9105
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Mod
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Res
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Pio
van
S.p
.A.
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.
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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
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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
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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
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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
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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
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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
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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.
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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
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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
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MDW Ser ies
Model Dosing VersionsStations Slide Gates Augers
MDW 20* 4 max 4
MDW 70 4 max 4 max 2
MDW 250 6 max 4 max 2
MDW 500 6 max 4 max 2
MDW 1000 6 max 4 max 2
MDW 1500 6 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
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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.
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