How customize a filling machine handle the filling of different ratios and viscosity of AB glue?

1.Case Background for AB Glue Filling Machine Technical Challenges

The client is based in Dubai, United Arab Emirates. His epoxy resin material A is paste-like, while material B is liquid. The materials come in two ratios: 3:1 (1000ml) and 4:1 (940ml).

To reduce costs, he aims to fill both ratios on a single workstation while requiring two separate filling and capping fixtures.

Other manufacturers in the industry fall into two categories: some simply lack the technical capability to develop feasible solutions and only offer two basic units; others can perform integrated design, yet the cost of their single filling machine matches that of two separate units. Consequently, within the industry, the most common approach for handling different filling volumes or even varying ratios typically involves configuring two separate machines. For first-time buyers, making this trade-off is challenging.

2.Maxwell's Advantages Over Competitors

As technical experts in this field, this marked our first time tackling such a complex challenge.

Previously, for clients requiring different filling volumes but identical filling ratios, we would configure one, two, or even three filling systems integrated into a single unit. Naturally, compared to a single automated filling and capping machine, this approach demanded greater design expertise and industry experience. Past cases have proven our significant success in such integrated designs, earning excellent feedback from clients.

Thus, we embraced an even greater technical challenge to meet the client's ideal configuration: acquiring a single machine to handle the filling and capping processes for products with different viscosities, filling volumes, and filling speeds.

3.Technical Challenges Involved in the Design of a Two-in-One Dual-Component Filling Machine

● 1) Independent Lifting

Requires two sets of independent lifting fixtures.

● 2) Independent Programming

Also necessitates rewriting two separate programs within the Siemens PLC system.

● 3)Budget Optimization

Simultaneously ensuring the cost of one machine is lower than two machines, as budget constraints are a key reason the client insists on a single system.

● 4)Independent Material Pressing

The differing flow properties of the two materials necessitate separately designed pressing systems.

4.Detailed troubleshooting process and customized solutions

To maximize the pre-simulation of the design proposal, we created 3D drawings after confirming with the client prior to issuing the order. This allows the client to visually inspect the basic appearance of the delivered AB adhesive filling machine, its component parts, and the specific functions each part performs.

Our team demonstrated exceptional professionalism, swiftly and precisely developing a customized solution. Below is the complete case demonstration.

1) A component high viscosity material filling system

For the paste-like Material A, we selected a 200L press plate system for material conveyance. Full drums of adhesive are placed onto the press plate base, which conveys the adhesive to the adhesive pump. Servo motor drive and metering pump interlock control the adhesive ratio and flow rate, coordinating with the automatic adhesive cylinder fixture to inject the adhesive into the cylinder.

2) B component liquid material filling system

For the free-flowing material B, we utilize a 60L stainless steel vacuum pressure tank for material transfer.

An additional material transfer pump is provided to facilitate the transfer of materials from the raw material drum into the stainless steel vacuum pressure vessel. High and low liquid level valves and alarm devices are installed to enable automatic transfer of Material B.

3) Heating system

Based on the customer's additional requirements, a heating function has been added, featuring high-temperature-resistant piping and heating elements integrated into the pressure plate.

4) Independent filling systems

For adhesive filling, we have established two independent filling and capping units. No tooling changes are required during operation. When switching materials, only the material tube interfaces need to be replaced, along with cleaning the pressure plates, thereby reducing labor costs.

5) Independent programming systems

For PLC control operations, we have also developed entirely new programming, implementing two independent systems to ensure simple and efficient operation for workers.

5.Fully Customized Service for AB Glue Dual Cartridges Filling Machine

From configuration proposals to finalizing drawings, from machine production to acceptance testing, every step is transparently reported. This enables clients to remotely monitor machine status in real time and adjust solutions based on their requirements. When it comes to epoxy resin adhesive two-component grouping machines, we deliver professional expertise and superior service. For epoxy resin AB two-component filling machines, choose MAXWELL.

6.Summary of Advantage Expansion for AB Glue Two Components Filling Machine

Maxwell assists startups or new production lines in overcoming technical challenges where a single machine must simultaneously handle two different filling viscosities, varying filling ratios, and diverse filling capacities. We provide comprehensive technical and equipment guidance solutions, ensuring smooth transition to mass production for dual-component filling machine manufacturers and eliminating all post-production concerns. For any technical challenges, feel free to reach out to us. Dual-component AB adhesive cartridge filling machine.