Many, More, Faster

Complexity made fast & simple
Applicon’s high volume, dual aisle industrial dispensary is designed for mixing and compounding plants that run many recipe mix cards or formulas, from a library of many, many ingredients. The Automated Batching System fulfills a 2,400 lb. recipe every six minutes ( 24,000 lb/hr), from sixteen active ingredients, and any number of hand weighed micro ingredients, accurately and without loss.

Major Ingredient FIBC Dispensing Stations
Eight stations use Applicon St-2 FIBC dispensers, each with a 1 or 2 ton chain hoist to lift a 40 to 60 cu.ft. bulk bag. Each hoist is radio controlled which allows allow the operator working atop the mezzanine (also built by Applicon) to lift/place/open and empty a bag, without having to descend. The hoists allow the operator to stretch and fully empty the bag, and even lower the empty sack to flatten the bag. Each station has a handbox door to access and untie or re-tie the bag spout without spill or dust emission. A second operator on the floor, or the forklift driver, removes the empty bag for return or disposal, and attaches the BLD bag lift device to a full bag already set on the floor by the forklift. Turnaround time to lift, place and open a new full bag is 2 to 3 minutes.

These stations each discharge to an Applicon 53 cu.ft. HDPE mass flow holding bin which holds an entire bulk bag. That large buffer insures that station will not be depleted, even for very high use ingredients. The bins are translucent HDPE, giving visual confirmation how full each bin is.

These major bins use the same body and frame as Applicon CVB cone valve bins, but without the Seal Cone. Instead of a bin unloader, these bins are equipped with Stir Bottom discharge, Single or Dual Auger feeder; or Shaker Feeder. These are designed to keep difficult powders moving, and prevent segregation in the bin.

Minor or Short Run Ingredient Dispensers
For ingredients that run shorter campaigns, eight more stations are fitted with Applicon PBU portabin unloader, and use Applicon CVB cone valve bins. Upon placing the bin atop it, the Unloader opens the CVB by raising the internal Seal Cone. Stored material descends in mass flow to the feeder below. The PBU can vibrate just the raised Seal Cone (vibration goes only into the stored material) and can vibrate the entire portable bin. Applicon also makes dispensing cells and unloaders for TOTE or similar metal portable bins.

Quick Ingredient Change
Any station can have the product changed in just a few minutes, by exchanging the Portabin with a different ingredient. Example: the Production Schedule calls for Station 3 to dispense 22 batches of Clay A93 at 180 lb. per batch, then Clay A93 will be unused for days or weeks. Upon that 22nd batch, the Portabin Seal Cone is closed. The forklift removes Clay A93 Pbin, which is now nearly empty, and places it under the mezzanine. The residual material in Station 3 is purged back to the Clay A93 bin from which it came. Station 3 is then oaded with a full Pbin of the next ingredient, say FireClay UF.

Quick change with low residual.

Accuracy in High Speed Weigh Batching
This system solves fulfilling a complex multi-ingredient batch in a very short period, by simultaneously weighing multiple ingredients, and weighing in scales matched to the amount required. Families of minor ingredients are metered into 4 (or 8) small volume, high resolution scale buckets. Concurrently, major ingredients are metered into 4 (or 8) large volume high capacity scales. Thus each of these sixteen (16) ingredients can be dispensed in only a few minutes, and still be within ½ % of the required recipe value.

Guaranteed Arrival
Careful weighing must be followed by careful delivery to insure that each precise weighment arrives in full at the mixer.

Applicon’s enclosed flexwall belt conveyor moves all automated products together to the Bin Filling station. Belt sidewalls and cleats keep the batch on the belt. A low belt speed and an elongated discharge plenum insure the entire batch exits the belt.

Manual for Micros
Careful handling of Micro-ingredients is even more crucial because the loss of even a few grams could drastically change the accuracy of fulfillment. Applicon Full Clean Bag Dump accomplishes complete transfer and capture of the Micros by conveying to a Vacuum Filter Receiver Scale, where the sum of the micro additions is checked. The micro batch is then deposited directly to the fill station below. The Majors & Minors can chase the Micros, or be deposited simultaneously with the Micros into the bin.

More Cone Valve
Applicon Cone Valve Bins are used to move batches from the Dispensary to skip hoists serving two high intensity mixers. The bin contents discharge quickly and completely, without operator intervention. The CVB recloses and is returned to the Filling Station, placed into the queue on elevated roller rails. The bin is rolled manually into the fill position, and is refilled in approx. 3 minutes.

Access and Maintenance
Applicon designs process system structures to be both ergonomic for the Batch Master and functional for maintenance. Access stairs and walkways allow safe movement around the system.

Contact Applicon for more information.