In-line blending system

In-line blending system

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Dosing, mixing and diluting!

Achieving precise mixing of ingredients to obtain the desired final product, while maintaining strict proportions, accuracy and order, poses a huge challenge for industrial manufacturers. The mixer was created precisely for this application. It makes production automatic, follows the recipe exactly and does not require human labor. The system is precise and records every operation.

The flow mixer is based on a system for diluting concentrated ingredients, such as SLES. However, it has been designed in a modular way. Thanks to this, we can easily configure the system to actual production needs. The ingredients of the final product can be taken from various types of tanks.

Dosing, mixing and diluting!

Achieving precise mixing of ingredients to obtain the desired final product, while maintaining strict proportions, accuracy and order, poses a huge challenge for industrial manufacturers. The mixer was created precisely for this application. It makes production automatic, follows the recipe exactly and does not require human labor. The system is precise and records every operation.

The flow mixer is based on a system for diluting concentrated ingredients, such as SLES. However, it has been designed in a modular way. Thanks to this, we can easily configure the system to actual production needs. The ingredients of the final product can be taken from various types of tanks.

Features and Benefits
  • Precise mixing according to predefined recipes saves on ingredient consumption.
  • Instant action provides a homogeneous and stable liquid over time.
  • Saving energy, time and space (compared to other mixing methods).
  • Continuous or batch delivery of the final product allows for precise production planning.
  • Continuous tracking and recording of operating parameters.
  • Local or remote control of the device.
  • Energy efficiency and reduction of the total cost of the final product.
  • Mixing mode allowing precise dilution of high-viscosity liquids.
  • Tank management mode provides production flexibility, allowing automatic switching between tanks for storing the final product, indicating when the supply tanks should be filled or replaced.
  • Flexibility and continuity of production.
Savings and efficiency

Our continuous flow mixing process offers a modern alternative to traditional mixing methods. By eliminating the need for manual addition and mixing of liquids, we streamline the process to save time and energy.

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 detergent or something else entirely.

Our device stands out for its precision. Unlike manual measurement of ingredients, it ensures accurate proportions, limiting ingredient waste. This precision contributes to cost savings in production while maintaining product quality.

Examples of supply tanks
Storage tanks IBC Pallet Containers Drums Dedicated tanks
Storage tanks IBC Pallet Containers Drums Dedicated tanks
Control system
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.

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.

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.

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

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

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

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.
  • Features and Benefits

  • Savings and efficiency

  • Examples of supply tanks

  • Control system

  • Precise mixing according to predefined recipes saves on ingredient consumption.
  • Instant action provides a homogeneous and stable liquid over time.
  • Saving energy, time and space (compared to other mixing methods).
  • Continuous or batch delivery of the final product allows for precise production planning.
  • Continuous tracking and recording of operating parameters.
  • Local or remote control of the device.
  • Energy efficiency and reduction of the total cost of the final product.
  • Mixing mode allowing precise dilution of high-viscosity liquids.
  • Tank management mode provides production flexibility, allowing automatic switching between tanks for storing the final product, indicating when the supply tanks should be filled or replaced.
  • Flexibility and continuity of production.

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