On-site Powder Dissolving Apparatus for Pellet Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing system for manufacturing and transporting liquids with dissolved or suspended powders is inefficient due to the weight and expense of transportation, as well as the deterioration of powders over time, leading to reduced effectiveness and safety concerns during handling.
Innovation Solution
A system comprising a mixing vessel, solvent supply, feeding, weighing, and control systems that allows for on-site production of liquids by dissolving or suspending powders in solvents, including a recirculation mixing system, vibrating feeders, and a Programmable Logic Controller for precise control and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If liquids comprising dissolved or suspended powders are manufactured off site and transported, then the liquid form enables easier application to feed or administration to animals, but the transportation and storage become expensive and complex due to weight
Solution Approach 1:
The system separates the powder and solvent into distinct components that are stored separately on-site. The powder is stored in a hopper and the solvent in a storage tank, only combining them when needed. This segmentation eliminates the need to transport heavy pre-mixed liquids while maintaining the benefit of liquid application.
Solution Approach 2:
The system prepares the liquid mixture just before use through automated mixing. The weighing system pre-measures the required amounts of powder and solvent, and the mixing system combines them immediately before application, ensuring the liquid is fresh and effective while avoiding prolonged storage and transportation.
2Ease of operation
If liquids are manufactured off site and transported, then the liquid form enables easier application, but the effectiveness of the liquid deteriorates significantly with time
Solution Approach 1:
The system performs the mixing operation immediately before application rather than in advance. The liquid is prepared on-demand through automated weighing and mixing, ensuring maximum effectiveness by eliminating time-related deterioration that occurs with pre-manufactured liquids stored during transportation.
Solution Approach 2:
The system automatically manages the entire mixing process on-site without requiring external preparation. The weighing system, mixing system, and control mechanisms work together autonomously to prepare fresh liquid mixtures as needed, ensuring consistent effectiveness regardless of time elapsed.
3Ease of operation
If containers are moved, connected, emptied, cleaned and disposed of, then the liquid can be applied, but the process becomes complex and requires lifting equipment due to heavy canisters
Solution Approach 1:
The system automatically handles all aspects of the mixing and transfer process without manual intervention. The weighing system automatically dispenses powder, the pump transfers solvent, and the mixing system combines them, eliminating the need for manual container handling, lifting equipment, and cleaning operations.
Solution Approach 2:
The system replaces manual mechanical handling operations with automated mechanisms. Instead of manual lifting and moving of heavy containers, the system uses a weighing system with automated dispensing, a pump for solvent transfer, and a control system that coordinates the entire process, significantly reducing device complexity and operational burden.
4Ease of operation
If powders are transported and handled, then they can be converted to liquid form for application, but handling powders creates harmful dust that reduces worker safety
Solution Approach 1:
The system extracts the harmful dust generation step from the process by performing mixing in a controlled, enclosed environment. The powder is weighed and mixed within the mixing system where dust is contained, and the liquid is transferred through a pump, eliminating the need for manual powder handling that generates harmful dust clouds.
Solution Approach 2:
The system replaces manual powder handling operations with automated mechanisms that contain dust. The weighing system automatically dispenses powder into the mixing vessel, and the pump transfers the liquid mixture, eliminating manual operations that would generate harmful dust and improve worker safety.
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
Enables the production of 'instantaneous' liquids on-site, reducing transportation costs and maintaining powder effectiveness, while improving safety by converting powders into a safer liquid form for easier application and handling.
Implementation Method 1
dissolving or suspending substances located in the mixing vessel (33) in a solvent by liquid recirculation
Implementation Method 2
dissolving or suspending substances located in the mixing vessel (33) in a solvent by liquid recirculation
Implementation Method 3
a hopper vibrator (3) for feeding a particulate material to the weighing tray (34)
Implementation Method 4
a weighing tray vibrator (4) for feeding the particulate material to the mixing vessel (33)
Data Source
AI summary
The present invention relates to apparatus for manufacturing at least one liquid, by dissolving or suspending powders in solvents. The apparatus may be arranged for inclusion in a pellet coating system to supply the liquid to a downstream apparatus such as a Post Pellet Liquid Application (PPLA, 44). The apparatus includes: a mixing system, comprising a mixing pump (27), a mixing vessel (33) and piping for mixing substances located in the mixing vessel (33) by liquid recirculation; solvent supply means, comprising a supply tank (37) arranged to supply solvent to the mixing vessel (33); a feeding system, comprising a Hopper (32) for storing a first particulate material, a ramp arranged above a weighing tray (34) and a hopper vibrator (3.1) for feeding a first particulate material to the weighing tray (34); a weighing system located above the mixing vessel (33), the weighing system comprising the weighing tray (34), a weighing tray loadcell (5) for weighting a first particulate material and a weighing tray vibrator (4) for feeding a first particulate material to the mixing vessel (33); a blending vessel (40) to which a liquid comprising the first particulate material is transferred from the mixing vessel (33) and to which additional solvent may be added to reach a desired concentration of the first particulate material in the liquid; optionally a day tank (39) to which a liquid comprising the first particulate material is transferred from the blending vessel (40.1) for storage; and a control system, wherein a Programmable Logic Controller (PLC) (25) is arranged to receive signals from the weighing system and to control operation of at least part of the feed system according to the signals received from the weighing system to deliver a target mass of first and at least a second particulate material to the mixing vessel (33). The apparatus for manufacturing at least one liquid according to the invention may be connected to system for coating pellets, such as feed pellets. The system for coating pellets may include: the apparatus for manufacturing at least one liquid; a pellet source; a pellet coating device; means for feeding at least one liquid from the manufacturing apparatus to the pellet coating device; wherein the pellet coating device is arranged to apply the or each liquid to at least some of the pellets received from the pellet source. The present invention includes a method for manufacturing a liquid, by dissolving or suspending powders in solvents.