Automated IBC filling for GfE with SysTec controller
The electrometallurgy specialist GfE offers around 250 material compounds on the global market, including vanadium-containing acids for energy storage systems. An automated filling system implemented for GfE by SysTec partner KESTERMANN GmbH is used for precise and fast filling of the acid into IBC containers. The powerful SysTec IT8000E filling controller, together with the FILL E application software, ensure high throughput.
Key facts
- Automatic gravimetric filling instrument (AGFI) with pallet conveyor technology for automated filling of IBCs
- Very high filling accuracy: up to 0.5% for 1,000 liter IBCs and a throughput of 20 IBCs per hour
- W&M approved liquid filling
- Robust SysTec weighing electronics
- PROFINET-PLC-connection
Products
- IT8000E: robust and flexible SysTec weighing indicator and controller for continuous operation
- SysTec FILL E application software ensures fast filling; software adaptation according to customer requirements
- High-performance KESTERMANN filling system, incl. assembly and service
Weighing electronics for filling line
Filling the liquid
The end customer: GfE
The Nuremberg-based company GfE Metalle und Materialien GmbH is part of the AMG Advanced Metallurgical Group N.V., Netherlands, a global leader in the production of specialty metals and metallurgical vacuum furnace systems. The core business of the GfE Group is the development and production of high-performance materials. The portfolio includes, for example, coating materials, alloys, metal powders, and chemicals.
Intermediate Bulk Container
Intermediate Bulk Containers (IBCs) play an important role in modern storage and logistics. Thanks to their cubic design, they make efficient use of storage space and can be easily transported from one location to another. The containers for liquid and free-flowing substances consist of a plastic tank and are often placed in a mesh cage.
The process
![[[Translate to "English"]] IT8000E SysTec Abfüllsteuerung](/fileadmin/public/Redaktion/Bilder/IBC_Filling/IT8000E-SysTec-Filling.jpg "[[Translate to \"English\"]] IT8000E SysTec Abfüllsteuerung")
As soon as the operator has entered the product number of the acid to be filled and the target weight, the system is ready for automatic filling using the bottom filling method. The interaction of the powerful SysTec weighing electronics, the PROFINET-PLC-connection, and the labeling system are important aspects for the smooth functioning of the system processes.
The IBCs are moved onto the roller conveyor of the system by forklift trucks and detected by a sensor. In the next step, the IBC is moved to the first turntable, where a hazardous goods label is applied. The IBC is rotated by 90° and transported to the filling and weighing station.
Precise alignment on the weighing platform is achieved by means of IBC centering. The screwing tool is positioned over the opening lid, which is screwed on, and the SysTec weighing electronics carry out the taring. First, the SysTec weighing indicator controls the coarse flow via the feed hopper and the filling lance according to the gravimetric principle and then reduces it to fine flow. The indicator also calculates the overrun. Once the target weight has been reached, the IBC lid is fitted and closed using a screwing tool.
The filling accuracy is approx. 0.5% for 1,000 liter IBCs and a throughput of 20 IBCs per hour. On the second turntable, the labeling machine applies the label with net weight, order, and batch number to the IBC. The IBC is ready for transportation.
Customer benefits
- Gravimetric filling method enables fast and accurate filling of large quantities
- Labeling system integrated into the filling line
- High-performance with W&M approved SysTec weighing controller / indicator
- Easy maintenance and cleaning: the system has a modular design and is made of stainless steel
- Storage of product files
- High operational and system safety, secure enclosure of the system
![[[Translate to "English"]] Kundennutzen](/fileadmin/public/Redaktion/Bilder/News/UMFRAGE-2022-720.jpg "[[Translate to \"English\"]] Kundennutzen")
Weighing indicator/ controller: SysTec IT8000E
- High ease of use: simple multilingual operator prompting, bright 5.7“ TFT color display with wide viewing angle and large-character weight display, alphanumeric keyboard
- W&M approved use as non-automatic and automatic weighing instrument possible (approved in EU, USA, Canada, etc.)
- Universal use: numerous standard application programs available
- Customizable: free programmability
- Robust: stainless steel housing (ingress protection IP69K)
- Ex-area: for hazardous areas SysTec offers the version IT8000E Ex2/22 and for zones 1/21 the IT8000Ex unit
- Various designs: wall-mount / desk-top version as well as panel-mount version
- Connection options: in relation to FILL E applications: connectable are 1 or 2 scales of different types with analog or digital load cells. Connection options for IT8000E in general: 2 internal and up to 16 external scale connections (NMi approval), can be integrated into PC networks via Ethernet or wireless LAN, connection to label printers and network printers, PLC connection via fieldbus
- High operational security: data storage power-fail safe, password protection, battery-backed real-time clock, remote diagnostics possible via Internet