Continuous Formulation Mixing With Real-Time Feedstock Adjustment
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Solution Overview
Problem
Existing production systems for formulations, such as paints, face challenges in accurately adjusting material properties due to non-constant raw material profiles and limited accuracy in weighing, leading to time-consuming batch adjustments and limited directional compensation.
Innovation Solution
A production system with a small-volume process mixer and buffer tank, equipped with measurement and evaluation units to continuously monitor and adjust feedstock inputs, ensuring formulations meet target properties by iteratively adjusting feedstock amounts based on real-time property deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch manufacture with subsequent adjustment is used, then formulation properties can be corrected, but the process becomes very time-consuming
Solution Approach 1:
The system performs preliminary actions by continuously monitoring formulation properties during manufacture and making real-time adjustments to feedstock addition rates, rather than waiting until batch completion to detect deviations and perform corrections. The evaluation unit continuously compares actual properties with target values and adjusts feedstock feeds beforehand to prevent significant deviations.
Solution Approach 2:
The system implements feedback control by continuously measuring formulation properties during manufacture, comparing them with target values, and using this information to automatically adjust feedstock addition rates. The evaluation unit provides real-time feedback on property deviations, and the system responds by modifying feedstock feeds to maintain target properties, creating a closed-loop control system that eliminates time-consuming post-batch adjustments.
2Manufacturing precision
If feedstocks are added to adjust material properties, then target state can be approached, but adjustment is limited to one direction only
Solution Approach 1:
The system applies dynamics by continuously varying feedstock addition rates in both directions based on real-time property measurements. Unlike static batch adjustment where only addition is possible, the dynamic continuous system can increase or decrease feedstock feeds moment-by-moment to achieve bidirectional property adjustment. The evaluation unit enables real-time control that adapts feedstock rates dynamically to reach target states from any deviation direction.
Solution Approach 2:
The system changes parameters by continuously adjusting feedstock addition rates as variable parameters during manufacture. Rather than being constrained to fixed batch compositions with limited post-manufacture adjustment options, the system modifies feedstock flow rates as controllable parameters to achieve precise property control in both directions, enabling versatile adaptation to different formulation requirements.
3Productivity
If continuous manufacture with real-time adjustment is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The system achieves universality by designing the evaluation unit and control system to handle multiple formulation types and property measurements through a single integrated platform. The same continuous manufacture infrastructure serves multiple product lines, and the evaluation unit can assess different formulation properties (viscosity, color, composition) using standardized measurement and feedback mechanisms, reducing the need for separate complex systems for each formulation type.
Solution Approach 2:
The system replaces complex mechanical adjustment mechanisms with automated electronic control and measurement systems. Rather than requiring manual intervention and complex mechanical dosing equipment for continuous adjustment, the invention uses electronic sensors, evaluation units, and automated feedstock delivery systems that simplify the overall device architecture while enabling precise continuous control and improving productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system enables efficient, continuous, and precise manufacturing of formulations, reducing the need for extensive batch adjustments and improving process efficiency by maintaining target properties throughout production.
Implementation Method 1
at least one measurement unit for ascertaining properties of a formulation manufactured continuously in the process mixer (kP)
Implementation Method 2
a small-volume process mixer (kP) for mixing of feedstocks, wherein the process mixer (kP) comprises a mixing device
Data Source
AI summary
Described herein is a production system including a unit, wherein the unit includes a subunit (1.1) for continuous manufacture of formulations. The subunit includes a combination of a small-volume process mixer and a buffer tank, means of feeding defined amounts of feedstocks into the process mixer, a measurement unit for ascertaining properties of a formulation manufactured in the process mixer, an evaluation unit for determining a deviation of properties of the formulation manufactured in the process mixer from the properties of a predefined target state, and a unit for adjusting the feed of feedstocks in view of the deviations. Also described herein is a process for manufacturing formulations.