Where traditional auger fillers have their place in filling applications specifically for the delivery of large doses of dry powdered or granular products, they are inappropriate for the delivery of small incremental doses with close-tolerance repeat accuracy. This however is not the case for the new Kinematics’ Model 5500/TX Bench Top Powder Filler. With its capability of cleanly and accurately delivering repeatable small doses of dry powders from 1 gm. to 180 gm. at fill rates of up to 25 fills/minute, its ability to achieve such a high level of repeat dose accuracy (often up to Six Sigma levels) is owed to the use of a constant vacuum which compresses the powders to a uniform density.
All features on the 5500/TX are directly driven. The Ø6.0″ O.D. shuttle disk is driven by a programmed stepper motor drive, whilst the product agitator shaft is driven directly by a small AC induction gear motor. Absent are the cumbersome clutches, brakes, belts, pulleys, bearings and gears that were part of earlier designs. In addition, all control relays have been removed from the PLC resulting in a significantly longer life expectancy of this component. Furthermore, the need, time and cost to replace a PLC will be non-existent. The control relays in the 5500/TX are robust, solid-state plug-ins, mounted on easily accessible DIN rail segments so if a relay fail were to arise, it can be unplugged and replaced without the need for a time and cost consuming engineer visit.
The front panel mounted, full colour, touch screen HMI enables the user to field-configure its operation by selecting one of five pre-programmed modes of operation:
1. Auto Cycle (Paced Delivery Mode)
During the auto cycle mode, powder doses are both automatically and repeatedly dropped from the shuttle disk at a fixed time interval chosen by the user. Once the sequence has started the machine will continuously drop the repetitive doses.
2. Foot Pedal Actuate (Single or Multi-Shot Fill Cycle)
This mode relies on a footswitch closure to initiate each dose cycle. Depending on the programme selected, the filler will deliver a single or multiple dose with a single depression of the footswitch. The foot pedal actuate mode is ideal for filling hand-held pouches.
3. Foot Pedal Actuate with Container Present Confirmation (Single or Multi-Shot Fill Cycle)
Similar to above, this mode also relies on a footswitch closure to initiate each dose cycle. However, the difference is that this mode does not allow delivery of a dose until there is confirmation of a container present at the fill station. Before the cycle can start, the container present sensor must be actuated, in the multi-shot mode, the container is held in place against the sensor until the programmed number of doses is entered. Once a cycle has been completed, the filled container is removed and replaced by a new empty container awaiting for the footswitch actuation. This mode is best used for filling rigid containers either directly or through the funnel assembly.
4. Container Actuate (Single or Multi-Shot Fill Cycle)
In this mode the container present sensor initiates the fill cycle itself, therefore no footswitch signal is required. Either a single or multiple dose is delivered each time a container is placed in position to receive powder against the container present sensor. The container is kept in position under the dose wheel until the total number of shots selected for the cycle is dropped. Once the container is removed this resets the PLC ready for the next fill cycle. The container actuate mode is ideal for quickly filling rigid containers filled either directly or through the funnel assembly.
5. Handshaking Mode (Integrated Automatic Fill Station)
When the rotary shuttle (5500/RS) is integrated into a larger, fully automated filling system, it operates in a symbiotic ‘hand-shaking’ mode with the host system’s PLC. The host PLC starts each fill cycle with a switch closure, delivers the dose and then actuates a relay which signals back to the host PLC that the cycle has been completed. A successfully completed cycle comprises a verified, full up and down index of the shuttle disk as well as verification that the powder charge was dropped. It is important to remember that the host PLC will be responsible for the integration of these independent cycles and for verifying container presence before it sends a start cycle signal to the filler.
When purchasing the 5500/TX you receive a 2-year warranty and the opportunity to choose specific features to aid your filler needs. These features include:
Base Machine, Model 5500/TX
As there is no container present sensor included in this basic configuration, the fill cycle is initiated by footswitch actuation. All product contact parts are certified to be made of 316 stainless steel and full documentation is included. Required tooling is sold as a separate item.
Tooling: At least one set of tooling, comprising a custom Ø6″ Shuttle Disk Assembly is needed to complete the basic filler. The fill chamber is bored and honed to meet the customer’s specific fill weight requirement however, dose weight is fully adjustable over a wide range within the chamber size for the tool.
Container Platform Assembly: This feature includes the container platform with integral grating assembly, slide in waste pan, container centring blocks, container present sensor and sensor cable. (Please note that this is requires the column assembly option for mounting.
Funnel Assembly: This assembly is used for filling narrow-mouthed containers or bags with doses of free flowing powder and requires the column assembly for mounting.
Column Assembly: This provides the means for supporting and adjusting the height of both the container platform assembly and the funnel assembly.
Large Product Hopper: This item is used to replace the small product hopper, allowing for fewer hopper refills when doing larger sized doses.
Low Product Level Sensor: This sensor adapts to either a small or large product hopper for detecting low product levels. Relay contact closure allows for activation of external audio/visual alert or actuation of an automatic refill means.