Color Save 1000 (Advanced Single Component Gravimetric Feeder)
It is a highly accurate & cost-effective single component master batch & additive gravimetric feeder for injection moulding(available with an internal weighing hopper), extrusion and blow molding machines, that offers significant cost-savings and production efficiency advantages for plastics manufacturers. It ensures homogenous feeding, regardless of material density changes or other dynamic parameters. Save up to 50% of your masterbatch (MB) costs by making the switch to the gravimetric ColorSave 1000.
Accurate & consistent shot to shot dosing reduces product rejects, maintenance time and additive waste. It uses a single vibrating channel to obtain consistent precision and accuracy. ColorSave-Micro supports many additive types. Granules, Micro-granules, Certain powders. It reduces calibration & maintenance time, as the single channel is used for all feed rates and is easily cleaned between jobs.
Easy to use and extremely reliable. It removes the need to calculate and manually adjust the feeding screw speed if the additive percentage or injection time is changed – as the system adapts automatically to the changed parameter. For extrusion applications, it operates similarly to a gravimetric feeder – where the desired throughput can be set according to Kg/hr or as a percentage of the total extruder throughput.
ColorSave 1000VS is reliable, accurate, cost-effective and easy to use. ColorSave 1000VS incorporates the following features and advantages to give you an effortless and economical solution for feeding your masterbatch, the volumetric way:
PowderSave-G is a gravimetric screw feeder especially designed to handle free-flowing and non-free flowing powders as well as other bulk materials. Feeding is accurate and simple to perform. PowderSave-G is mounted on a weighing plate connected to LIAD’s controller. You need to simply define your desired flow rate (set point) and the controller will continuously monitor and control the material flow, automatically adjusting motor speed and the screw according to the predefined set point.
PowderSave-V is especially designed to handle free-flowing and non-free flowing powders as well as other bulk materials. Filling is quick, accurate and simple to perform – all you need in a screw feeder.
LiquidSave is a gravimetric dosing system designed for precise dosing of liquids on any plastics processing machine, including injection molding, blow molding, or extrusion applications. LiquidSave is extremely accurate, utilizing continuous loss-in-weight metering technology with closed-loop pump speed control.
BatchSave(Gravimetric Batch Blender)
It is a compact, effective, and highly reliable gravimetric batch blender; providing factories accurate and optimal blends. It is easy to use, and works perfectly with injection molding, extrusion or blow molding machines. Operation : Each material is fed separately into a weighing hopper, with the weight continuously checked by the controller against the predefined values. The weighed material is then dispensed into the mixing chamber, which delivers a homogeneous blend.
Material Hopper It can incorporate up to 4 hoppers for primary materials using free fall feeding via pneumatic valve, and up to 2 hoppers for additives via screw feeding. All material hoppers include outlets for easy emptying and fast material changes, and transparent windows to allow visual inspection.
Weighing Hopper Using a single load cell, the weighing hopper is designed to guarantee exceptionally high accuracy of ±0.1%. The hopper is fully removable and allows for simple maintenance and cleaning.
Mixer The unique design of the effective mixer has no stagnation areas, assuring superior and homogeneous blending. The mixer can be removed without pellet leakage for simple and quick cleaning.
Construction The modular construction guarantees high flexibility, enabling selection of the desired number of components. It has been designed so that it can be simply installed directly on the processing machine or on a special stand to feed one or more machines. A wide transparent door enables access to all parts as well as visual inspection of the system's operation. A safety micro switch prevents operation if the door is open.
Control The sophisticated PLC controller monitors the overall operation of the system. Every batch is followed by an automatic recalibration and error correction if necessary, assuring extreme accuracy of the blending process. The user-friendly touch screen facilitates easy setting, operation, and monitoring, while the controller is compatible with MODBUS over TCP/IP communication, and can seamlessly interface with LIAD-View monitoring PC software.
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.
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.
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.
FlowSave fulfills the extrusion sector's demands for accurate and homogenous dosing and constant blending, by providing highly accurate loss-in-weight blending and feeding of various size and bulk density materials such as pellets, regrinds and powder. Production range up to 1500 kg/h, and can feed up to 5 materials. Separate load cells for each component allow for constant monitoring of each component flow. If there are any changes in properties, e.g. bulk density, pellet size, etc., FlowSave automatically adjusts individual feeders to match the extruder rate at the required ratio - without affecting the accuracy of the blended material. This ensures a constant blending ratio according to the recipe at all times.
Design FlowSave is a modular system, whose feeders can be exchanged or removed as needed. FlowSave's design guarantees a totally homogeneous blend. The frame protects the dosing stations from the extruder’s movements and vibration.
Precision FlowSave’s high resolution weighing system allows precise low-rate additive feeding. Material flow is continuously monitored, while the controller automatically regulates the rotation speed of the dosing screws; ensuring a precise and homogenous blend of materials.
Gram/meter monitoring Using a shaft encoder, FlowSave can monitor the throughput in term of gram/meter. By continuously measuring the material flow (kg/h) by means of a loss-in-weight method, and by monitoring the product speed (m/sec), FlowSave translates the throughput to terms of gram/meter. The gram/meter monitoring allows easy monitoring for the operator.
Extruder Control FlowSave’s controller can supply a continuous control signal to the extruder's controller, which controls the extruder rpm to ensure the required pre-set throughput. FlowSave changes the extruder's speed to meet the desired throughput, and simultaneously adjusts the screw speed of each component to ensure a constant ratio of the material at all times.
PelletSave is a modular central blending and feeding system for multi-ingredient/multi-processing-machine combinations. The system’s central mechanical dosing structure provides highly accurate blending ratios, and when combined with its innovative control software, enables preparation and conveying of the required weighed batch to each of your plant's processing machine - according to each specific job requirement. PelletSave offers factories a complete solution for all procession machines, both big and small, with one simple operation method for all.
PelletSave is composed of the following sub-systems (see schematic system layout):
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