Precisely dosed innovation for Optolith Bauprodukte

Key take-aways:

• When choosing a dosing and filling solution for the production of primers, precision, diversification, and automation are key. To meet these requirements, BIBUS MENOS developed a new solution for Optolith.
• The new system addresses the weaknesses of the previous technology with a series of innovations. These include process control via weight instead of volume, doubling the number of dosing heads, and extensive automation.
• The new system offers Optolith a wide range of advantages: increased production capacity with lower resource consumption, lower costs, and greater flexibility to meet specific customer requirements.

Committed to progress for centuries

The activities of the German family-owned company Hufgard date back to 1720. Since 2004, Hufgard Optolith Bauprodukte has been supplying various markets with innovative solutions for construction chemicals from its base in Poland. In addition to paints, exterior plasters, adhesives for thermal insulation systems, construction cements, tile adhesives, sealants, substrate mortars, and renovation materials, the product range also includes primers for surface pretreatment. Efficient dosing and filling systems play a key role in their production.

Production of primers: No compromises on efficiency

In the competitive market for construction chemicals, manufacturers cannot afford to compromise on competitiveness. Precise, automated dosing, filling, and labeling systems are an important efficiency factor in the production of primers. The following criteria are central when choosing a technology:

• Precision: During filling, the loss of base material should be kept to a minimum, among other things to save costs and avoid material wear as much as possible.
• Diversification: Manufacturers of construction chemicals such as Optolith supply many different customers, who usually require different, specific product versions (own formulations, special properties, etc.).
• Automation: There is no way around automated production on the path to optimized production. Automation allows larger quantities to be produced with fewer resources.

Until now, Optolith used a filling system with two dosing heads in the production of primers. Due to a lack of accuracy in the filling quantity or dosing, excess material repeatedly leaked from the containers being filled. The excess material that had to be transported back into the IBC led to increased wear on various machine elements, which in turn led to leaks and even greater inaccuracy in dosing. To break this vicious cycle, Optolith turned to BIBUS MENOS for the development of a new solution. The two companies have a long-standing partnership.

It's all about weight

Optolith likes to draw on BIBUS MENOS's combination of technical expertise and broad supplier network, especially when developing special solutions. Both components came into play in the development of the new dosing and filling system for alkali-resistant primers. The result is a largely automated solution with a number of innovations:

• Number of dosing heads: Instead of two, the new system has four dosing heads. This enables four primer containers to be filled simultaneously.
• Weight instead of volume: The new filling process is based on precise weight control. In addition to precision, this also ensures that customer-specific containers (different shapes, sizes, etc.) can be used.
• SCADA: The integration of the existing Supervisory Control and Data Acquisition (SCADA) system, also developed by BIBUS MENOS, ensures continuity in monitoring, control, and data acquisition.

The new system solution also includes fully automatic cleaning. BIBUS MENOS collaborated with several long-standing partners to develop the dosing and filling system: THOMSON (linear technology), Camozzi (automation), CKD (valves), Elk (drive technology), and item (aluminum profiles). In addition to consulting and supplier selection, BIBUS MENOS also provided development/engineering, design, cabling, automation, testing, start-up support, and the labeling machine. The close collaboration with Optolith also includes comprehensive service and support for the ongoing operation of the new system.