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Fully Automated Production of MB from SPD’s & Optimal Flow Management of Materials

BlendSave™ is LIAD’s patented centralized blending and weighing system. BlendSave creates new homogeneous masterbatch from a combination of mono-masterbatches (SPD’s).

BlendSave operates by simultaneously weighing all needed resins and SPD’s for each recipe within its 14 weighing chambers, each of which is dedicated to a specific raw material, and then releases the entire batch into a common funnel for conveying to the corresponding extruder. LIAD achieves superior batch uniformity by placing a particular mixer within the free fall hopper connected to the inlet of each extruder.

For masterbatch manufacturers with tens of different SPD’s LIAD integrates multiple BlendSave units into a single system linked via a PC-linked controller to establish a fully automated production of new masterbatches from combinations of SPD’s. The funnel of each of individual BlendSave of the integrated system releases the weighed recipe into a second common funnel. The complete batch is then sent via an automatic manifold and tubing to the corresponding extruder.

When considering the possibility of integrating 3 BlendSave units to handle 42 ingredients, the total required floor space is only 15 sqm.

Plastic Plant Inventory Reduction in collaboration with SPD’s manufacturer

BlendSave is not solely for classic SPD’s producers, but may also be used by large plastic manufacturers in collaboration with the SPD’s providers to create new masterbatch colors as needed on-site, while keeping only a limited inventory of SPD’s.

Unmatched Accuracy and Uniformity

For applications where weight accuracy is of utmost importance, such as masterbatch compounding by combining SPD’s, BlendSave provides consistent, high-resolution weighing within 0.01g utilizing a multi-step process and small load cells.

Following the highly accurate weighing, the complete batch is dropped into a common funnel and automatic manifold and passed through a mixer within the free fall hopper located at the extruder inlet to ensure optimal batch uniformity.

This highly-accurate and fast flow enables BlendSave to service manufacturers most demanding requirements.

Switching Jobs & Contamination Prevention

BlendSave’s dedicated weighing chambers per raw material are fed directly from the materials silos, eliminating the need for sterilization and making the entire process of switching between jobs exceptionally smooth. As an additional measure, BlendSave uses a vacuum system and a high-pressured air blast between each batch to sterilize the common funnel and distributor pipe of the automatic manifold.

Program Monitoring

By utilizing BlendSave, factories have access to continuously updated information concerning equipment and material efficiency. As all the raw materials flow through a common system, BlendSave affords managers full monitoring and control of job status, batch auditing, historical graphs and performance reports for each machine and job via an interactive PC dashboard.

Conclusion

BlendSave enables factories producing masterbatches from SPD’s to improve efficiency by simplifying the flow of raw materials. Man-hours which used to be spent on batch preparations are dramatically reduced.

BlendSave enables factories to produce faster and with greater quality and control, opening new opportunities for growth and efficiency.

About LIAD and its innovative breakthrough technologies

LIAD Weighing and Control Systems, a veteran engineering company with over 35 years’ experience in the plastics industry, is recognized for innovative products which significantly improve plant efficiency. LIAD was the first company to introduce about 15 years ago a gravimetric feeder adjacent to the extruder inlet for precise and controlled dosing of masterbatches and additives.

In addition to BlendSave, LIAD is now introducing three more innovative breakthroughs in plastics manufacturing which promise to increase efficiency further and generate greater factory profit.

  • ColorSave-Micro™ - LIAD’s next-generation single component gravimetric masterbatch/additive feeder works with all types of masterbatches. The system reaches accuracy to within a single pellet, (http://www.liad.co.il/products/feeders/ColorSave-Micro).
  • SpectroSave™ - A multi-channel in-line spectrometer that integrates within the production line, providing on-site and real-time QA of colors, (http://www.liad.co.il/products/qc/spectrosave).
  • ColorSave-Spectro™ - A single component masterbatch feeder controlled by SpectroSave, and capable of instantly adjusting the release of colored masterbatches to obtain the desired color most efficiently.