Blending stations for polyol and additives
Polyol formulation is a sensitive process, requiring approved input materials, highly qualified personnel and reliable blending stations. The quality of the PU systems is extremely important either for the system houses or end users who use ready system polyols for their internal applications.
H&S blending stations designed for the batch method are mostly used for formulating the components for all kinds of PU applications where it is necessary to blend polyol with liquid additives (catalysts, stabilizers etc.). H&S blending systems enable high dosing accuracy of the components due to their optimal design: The systems comprise a pre-blender for the small amount of additives and main blender for the original polyols. Load cells for both blending tanks are responsible for the precise weight control.
H&S blending stations are easy to operate due to the high level of automation of all relevant processes such as filling the blending tanks with raw materials, dosing, agitating, protecting against overfilling, temperature control, discharge etc. The ready polyol blend can be transferred either to the intermediate storage tank, tank truck or into drums and containers by means of a specially designed H&S filling station.
Due to the user-friendly visualization, the H&S blending stations are extremely easy to operate. The recipe management named "H&S Batch Control"
is flexible and enables storage of a large number of recipes as well as recording of the results, control of all system parts as well as switching between manual and automatic operating mode if modifications are required. Every step of the process can be programmed and modified respectively with the recipe features. The innovative inventory control enables recording and visualization of the consumption of all raw materials across the specified period, as well as preparation of a precise purchase plan for the stock of raw material.
The control system comprises a track function for all batches for simplified monitoring of the production control. All functions of the "H&S Batch Control" system are targeted at achieving the highest possible repeatability and improvement of the quality management. In addition to the advantages above, the in-house blending also contributes to minimizing production costs. The purchase of original polyols and additives is cheaper than the purchase of ready-formulated polyols and provides savings of up to 15%.
Many H&S customers from all parts of the world successfully use the blending systems for different applications. The majority of blending stations was supplied for applications such as flexible and rigid foam products, aerosols, CASE etc.
Basic and optional devices for H&S blending stations comprise:
- Blending and pre-blending vessel made of stainless steel
- Safety trough for system protection in case of leakage
- Platform for the pre-blender
- Agitator for optimum homogenization of the material
- Pumps for original polyol and additives
- Temperature control unit (if required)
- Safety valves for protecting the reactor vessel against overpressure and negative pressure
- Automatic valves
- Shut-off valves
- Ultrasonic level control system
- Load cells
- Overfill protective device
- Temperature sensor
- Pressure sensors
- Pipe system
- Wiring of the complete module
- Control cabinet with modern Siemens PLC and operating console or PC, user-friendly control functions and recipe management