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BlendSave is an advanced multi-channel batch compounder that’s enabling plastics manufacturers and mono-masterbatch compounders to optimize their raw material flow management.
BlendSave is a centralized blender consisting of up to 14 individual weighing chambers which are all individually fed directly from silos or containers. After weighing and dropping into a common funnel, the materials are distributed as whole batches to the appropriate processing machine.
Designed for the creation of new homogeneous masterbatch from a combination of mono-masterbatches, in addition to meeting the needs of plastics batch compounding for plastic processing machines, BlendSave works by simultaneously weighing all needed resins and additives for each recipe within its 14 weighing chambers dedicated to a specific raw material, and then releases the entire batch into a common funnel before being sent via tubing to the corresponding processing machine.
As opposed to the traditional gravimetric batch blender which is limited to the number of machines it can serve due to the multitude of formula variations, a single BlendSave takes up only a few meters of floor space and supports up to 48 processing machines.
For applications where weight accuracy is of upmost importance, such as masterbatch compounding by combining mono-masterbatches, 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 passed through a mixer within the free fall hopper located at the extruder inlet to ensure optimal batch uniformity. (An optional automatic manifold can be added for required workflows.)
This highly-accurate and fast flow enables BlendSave to service manufacturers with the most demanding requirements.
BlendSave is unique in that it enables multiple systems to intercommunicate, thereby creating a platform that is theoretically unlimited in how many raw materials and color recipes can be processed, and how many processing machines can be supplied.
Manufacturers with tens of different raw materials can integrate multiple BlendSave units into a single system linked via a PC-linked controller. The multiple systems are raised on a platform, such that the funnel for each individual system releases the weighed material into a second common funnel utilized by all systems. The complete batch is then sent to its corresponding processing machine.
BlendSave is not solely for classic masterbatch producers, but may also be used by large plastic manufacturers in collaboration with their masterbatch providers to create new masterbatch colors as needed on-site, while keeping only a limited inventory of mono-masterbatch granules.
Switching Jobs & Contamination Prevention
BlendSave’s dedicated weighing chambers for each raw material fed directly from the material silo eliminates the need for batch blender sterilization, and makes the entire process of switching between jobs exceptionally easy. Furthermore, BlendSave uses a high-pressured air blast within the common funnel between each batch to sterilize the area and prepare for the next batch of raw materials.
In typical plastics manufacturing, as the mixed batch is released from the gravimetric batch blender and conveyed via the delivery tube to the corresponding processing machine, it is assumed that the components of the batch are significantly blended when they enter the processing machine. However, this assumption doesn’t take into account that as the batch is vacuumed from the gravimetric blender, the materials will separate according to their specific weight, and the batch will no longer be sufficiently mixed. BlendSave achieves superior batch uniformity by placing a mixer within the free fall hopper connected to the inlet of each processing machine. Regardless of tube distance or vacuum pressure, the batch enters the injection machine thoroughly mixed.
Production Speed & Batch Accuracy
Standard gravimetric blenders weigh batch components in a serial order. Each component is dispensed separately into a single, common weighing chamber, from which they are all subsequently dropped into a mixing chamber before being vacuumed to their respective injection line. This method of serial weighing limits the speed with which a blender can release a batch.
BlendSave improves production plastics job management speed by dedicating a weighing chamber for each individual bin; weighing in parallel all batch components. In addition to the enhanced speed and time savings by eliminating the risk of batch contamination, BlendSave uses smaller load cells; affording higher batch accuracy with a relatively high throughput.
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