In-line Blending System
Achieving precise ingredient blending for the desired end product, while maintaining strict proportions, accuracy, and sequence, poses a formidable challenge for industrial manufacturers. The In-line Blending System was created exactly for this application. It makes the production automatic, produces exactly by the recipe, and requires no human work. It is precise and it records every operation.
The In-line Blending System is based on the machine used to dilute thick liquids, like SLES. However, it was designed in a modular way. Thanks to that, we can easily configure the system to the actual needs for production. The ingredients of the final product can be supplied from various types of tanks.
Implementing our solution brings significant reduction of your production time and costs, while fully automating the operations. This allows to scale up production capacity, increase the profits, and remain – or potentially elevate – the final product quality.
FEATURES AND BENEFITS
Achieving precise ingredient blending for the desired end product, while maintaining strict proportions, accuracy, and sequence, poses a formidable challenge for industrial manufacturers. The In-line Blending System was created exactly for this application. It makes the production automatic, produces exactly by the recipe, and requires no human work. It is precise and it records every operation.
The In-line Blending System is based on the machine used to dilute thick liquids, like SLES. However, it was designed in a modular way. Thanks to that, we can easily configure the system to the actual needs for production. The ingredients of the final product can be supplied from various types of tanks.
Implementing our solution brings significant reduction of your production time and costs, while fully automating the operations. This allows to scale up production capacity, increase the profits, and remain – or potentially elevate – the final product quality.
Examples of final products: Bleach variants, Thick Bleach, Fabric Softeners, Shampoos and Hair Conditioners, Liquid Soap, Cosmetics like body lotions, Perfumed Body Sprays, Hand Sanitizers, Car cosmetics, or Flavoring Agents.
Dilution applications: Surfactants (for example SLES) solutions, Hydrogen Peroxide (H2O2) solutions, Ammonia Water solutions, Acids solutions, Alkaline solutions, Solvent Mixtures, Adhesives solutions.
Our in-line blending process presents a modern solution to the traditional methods of mixing. By removing the need for manual liquid addition and stirring, we’re streamlining the process to save you both time and energy.
The immediate availability of the final product is a significant advantage, reducing the time required to create a batch of the end product – whether it’s a detergent or something else entirely.
Our system’s precision sets it apart. Unlike manual ingredient measuring, our process ensures accurate proportions, reducing ingredient waste. This precision contributes to cost savings in production while upholding the product’s quality.
Storage tank |
IBC container |
Drum |
Customized tanks |
| The system is controlled by a programmable logic controller (PLC) and a human-machine interface (HMI) built into the cabinet. The HMI allows the operator to monitor and control the system’s operation by selecting one of the recipes and achieving the desired flow rate, batch volume, or other parameters. The control program’s functions make it easy to operate and maintain, and the high process safety and time savings ensure consistent and reliable operation. |
![]() Main program screen indicating device status and water level in the tank. |
The control program offers the following modes:
| 1. Recipe Manager: This mode allows for the creation and storage of unique end-product recipes. During recipe creation, you can specify the semi-finished products to be included in the mixture and their respective percentages. Recipes are securely stored in the controller’s memory and can be easily selected for batch production. | 2. Blending Manager: The blending manager helps operators effectively plan the blending and production process of the final product. Using this interface, operators can designate the desired batch volume based on predefined recipes. Furthermore, operators have the flexibility to organize the sequence of operations, which is particularly beneficial when filling multiple tanks. This feature enables precise allocation of the final product to multiple tanks, along with determining the filling order (e.g., tank 1: 15 tons, tank 3: 20 tons, tank 2: 10 tons, then stop). This window also serves as a real-time production progress monitor, offering insights into key production parameters.
![]() Blending Manager screen with filling sequence selection and status information. |
3. Level Control: The level control function offers real-time monitoring of liquid levels in both the supply tanks and the storage tanks used for the final product. This option provides operators with a simple way to confirm the fill status of each tank, eliminating the need for external tools. Additionally, this mode allows for the configuration of low-level warning thresholds for the supply tanks. With this feature, operators are immediately notified of the need to refill or replace smaller tanks, such as IBC totes or drums. The level control mode also manages the levels of storage tanks, effectively preventing potential overflow scenarios.
![]() Level control screen with detailed information on each of the tanks used in the mixing process. |
4. Main Parameter Charts: The control program includes comprehensive charts illustrating key parameters: flow rates and pressure levels of the pumped liquids. It also offers insights into the status of essential components, such as pumps and valves.
![]() Charts screen |
5. Produced Liquid Counters: The control program includes counters to track the amount of liquid consumed, as well as the amount of final liquid produced. This provides an easy way to monitor system performance and ensure it meets production requirements. Included is one counter that can be manually reset after each batch, and a second, non-resettable counter that provides information on the total system output.
![]() Counters screen |
6. Error History: The control program logs any errors or malfunctions that occur during operation, along with the date and time of their occurrence. This allows for easy troubleshooting and system maintenance.
![]() Alarms screen |
| 7. Production Reports: Upon completion of each production batch, an Excel file containing a detailed production report will be generated. For added convenience, a USB port will be provided for quick file downloads. This process ensures easy documentation of production performance for reporting purposes. | 8. Remote Support Module: The system comes with a remote support module, enabling online startup and immediate assistance from our motorers. Once the system is installed and connected to the required utilities, our motorers can assist with the initial startup and ensure the system is operating correctly. |
Examples of final products: Bleach variants, Thick Bleach, Fabric Softeners, Shampoos and Hair Conditioners, Liquid Soap, Cosmetics like body lotions, Perfumed Body Sprays, Hand Sanitizers, Car cosmetics, or Flavoring Agents.
Dilution applications: Surfactants (for example SLES) solutions, Hydrogen Peroxide (H2O2) solutions, Ammonia Water solutions, Acids solutions, Alkaline solutions, Solvent Mixtures, Adhesives solutions.