Feeding systems for continuous adhesive production processes
Adhesives play a key role in many industries. For example, 15 to 18 kilograms of adhesives are used to make just one car. Production of adhesives is crucial to the success of many manufacturers who use a wide range of different adhesive products. “Large producers of adhesives are increasingly switching from batch to continuous production processes, given that the latter may be better in technical and energy terms”, says Michael Weller, Sales Manager at Brabender Technologie. “Brabender Technologie provides complete, application-specific feeding systems, from planning and design through commissioning.”
Profound understanding of processes and materials
As a specialist in solid and liquid feeding systems for a wide range of various applications, Brabender Technologie has a profound understanding of processes and materials. Liquids, granules and powders need to be dispensed extremely accurately to produce adhesives. Liquids like resins, silanes and other fluids usually require very specific feeding solutions, given that process systems must cope with different viscosities, temperatures and injection pressures. To meet this need Brabender Technologie develops special liquid feeders that exactly match the relevant requirements. “Our twin-screw and FlexWall feeders are regularly used for powders and granules. Where solid resins are used, vibrating tray feeders are selected due to their superb material-conserving properties”, Michael Weller states. When standard devices are not enough, customized solutions are also utilized. Brabender Technologie’s can also offer critical feeder refill products.
Brabender Technologie provides feeding system control solutions for these applications as well. “We offer a stand-alone control system with its own visualization function," the expert explains. Cp and CpK process capability indices can also be calculated using the control system. These are KPIs used in the statistical evaluation of a process that indicate to what degree of certainty specified targets are achieved. These calculations are particularly important to the vehicle manufacturing industry.
Pre-assembly for fast installation
The provision of turnkey solutions also includes prefabrication of entire modules. The company designs the feeding systems, manufactures the equipment and pre-assembles large-scale systems in individual groups. “We wire up the components as far as possible in advance to make on-site installation an uncomplicated process”, the experts relates from practical experience. “We already test systems in our Technical Center beforehand, to enable setup and commissioning to be completed quickly.”
The market for these applications is huge, as evidenced by Industrieverband Klebstoffe e.V. figures for the 2016 fiscal year. “The German adhesives industry generated total sales of 3.7 billion Euros for all adhesive systems in the 2016 fiscal year.” According to the association, annual sales of adhesives and sealants, cement-content building materials and adhesive tape amount to some 61 billion Euros worldwide. As a proportion of total production volume, dispersion adhesives were the most important product type in 2016 at a production quantity of 420,000 tons. These were followed by reactive adhesive systems at 250,000 tons and hot-melt adhesives at 150,000 tons. The most important markets for adhesives included paper & packaging, vehicle manufacturing, timber, electronics and construction.