Real-time viscosity control and multi-component dosing for the sandpaper industry | FlexoKing FT-44 Triple
Maximum process control for consistent coating quality
In the sandpaper industry, viscosity directly influences coating quality, abrasive grain adhesion and the mechanical performance of the final product. Even small deviations can affect layer thickness, material consumption and overall product consistency. A stable and fully controlled production process is therefore essential.
For a customer in Finland, Gemini Techniek developed the FlexoKing FT-44 Triple, a custom dosing and mixing installation in which dosing, mixing and real-time process control are fully integrated. Continuous viscosity measurement and automatic solvent correction ensure consistent batches and reliable product quality.
The technical challenge
The customer required a fully automated dosing and mixing installation for producing advanced adhesive formulations. Liquids and powders needed to be dosed simultaneously and directly into the mixing vessel without manual intervention or process interruptions.
Key requirements included:
- Batch sizes from 100 to 1,000 kg
- Dispensing accuracy of 50–100 grams
- Direct transfer of each batch to the coating head
- Continuous viscosity monitoring with automatic control
- Fully automated operation without manual corrections
Due to the complexity of the process, a standard solution was insufficient and a fully engineered custom system was required.
The solution : FlexoKing FT-44 Triple
The FlexoKing FT-44 Triple is a custom-engineered multi-component dosing and mixing system designed for complex formulations. The installation handles 34 liquid components and includes 10 spare positions for future expansion.
Floor-mounted weighing scales with a 1,500 kg capacity combined with central PLC control ensure high dosing accuracy across the entire batch range.
Key features
- Stainless steel storage tanks in multiple volumes
- Selective tank heating based on product requirements
- Three central dosing points for simultaneous component feeding
- Direct batch transfer to the production coating line
- Central PLC control for reproducible operation
The result is one fully integrated industrial dosing and mixing platform rather than separate subsystems.
Real-time viscosity control during mixing
Three integrated Gemini ViscoMixer units continuously measure viscosity throughout the dosing and mixing process. Measurement data is compared with product-specific dilution curves stored in the control system.
When deviations occur, solvent addition is automatically adjusted. This eliminates manual corrections and stabilizes production.
All process and measurement data are logged in the HMI system, ensuring:
- full process transparency
- complete traceability
- reproducible batch results
Result: stable production and consistent product quality
By combining automation, real-time monitoring and intelligent process control, the customer achieved full control over production.
Key benefits include:
- Continuous real-time viscosity control
- Accurate multi-component dosing up to 1,000 kg batches
- Automatic solvent adjustment without operator intervention
- Reduced batch deviations
- Improved process stability and consistent product quality
By integrating dosing, mixing and viscosity control into one automated system, quality is ensured at the source of production.
Engineering tailored to the production process
Gemini Techniek develops dosing and mixing systems fully aligned with modern production requirements. From concept engineering to commissioning, every installation is designed for reliability, scalability and maximum process control.
Looking to optimize a production process?
Gemini Techniek engineers analyze process requirements and design a tailor-made solution.
FAQ
What is real-time viscosity control?
Real-time viscosity control is a process in which product viscosity is continuously measured during mixing and automatically adjusted. Direct feedback to the control system allows solvent addition to be corrected automatically, ensuring consistent product quality.
Why is viscosity control important in coating processes?
In coating processes, viscosity directly affects layer thickness, material distribution and adhesion. Even small deviations can lead to quality variations and increased material consumption. Continuous viscosity monitoring ensures a stable and reproducible production process.
What is multi-component dosing?
Multi-component dosing is the precise and simultaneous dispensing of multiple liquid and/or powder raw materials within one automated system. This enables complex formulations to be produced reproducibly while reducing manual handling.
Which industries use dosing and mixing systems with viscosity control?
Systems with integrated viscosity control are commonly used in:
- abrasives and sandpaper industry
- coatings and paints
- adhesives and sealants production
- chemical processing industry
- food production processes
When is a custom dosing system required?
A custom dosing system becomes necessary when standard installations cannot provide sufficient process control, for example with complex formulations, high accuracy requirements or advanced process automation.
