MasterMix

Elimination of hand measuring and mixing significantly improves quality control issues. Package units are supplied as a ‘System in a Box’, however some on-site hose connections are required and mounting of the Mix Manifold on the application device will be the responsibility of the customer, as will connection to a suitable supply of compressed air.

Adhesive delivery rates are readily adjustable and depending on set-up units are capable of delivering 8 Litres or more of mixed adhesive per minute. As with all 2K Proportioners, one Proportioner is required for each Applicator Head.

How can MasterMix improve your Adhesive handling system?

• Reduce wastage
• Increase production
• Mix ratio assurance
• Consistent adhesive
• Application volumes
• Consistent results consistently.

Each system is sized and engineered to achieve the correct dispense rates and application requirements for the customer, whether this be fully automatic or manually controlled. Start /stop operations can often cause ratio fluctuation, MasterMix design overcomes these off ratio situations allowing ongoing confidence that your product is manufactured to the design standard.

This being the case it is often with amazement that we see hot potting and paddle mixing of high tech adhesives in applications that often require the timber producer to offer long warranty and performance contracts.

MasterMix is helping over come these issues, often payback is within months of installation, correct adhesive application and handling reduces product failures, increases yield per liter of adhesive and reduces down time and overall house keeping requirements.

As the MasterMix system is fed with filtered resin directly from the adhesive supply container there is a constant on demand supply of resin to your applicator head. How often and long is your plant stopped waiting for the next batch of adhesive to be mixed? How often is the applicator head partially blocked with semi cured adhesive, how much product have you produced with a partially blocked applicator, when will these problems be picked up? on the stacker, in the yard or at the customers.

These are all issues MasterMix can help your company overcome. How many hours a week can you get out of the finger jointer are you being sold short by poor housekeeping, over use of adhesive and poor adhesive mixing. With MasterMix the resin and hardener are mixed through a static mixer, these mixers divide the adhesive flow in two with every element, as an example a 24 element mixer will mix the adhesive @2 to the power of 24 or over 16 million times in 12 inches of mixer, that's far better than you can ever achieve with a paddle.

As mixing is achieved on a flow basis mixing need only take place as the adhesive exits the mixing manifold and enters the applicator.

Is this how your
glue room looks?

Each time the applicator head turns on, fresh adhesive flows through the static mixer purging the mixer each time it turns on. Pot life alarms should be incorporated to give warning if the system is left inactive for periods. Automatic and manual clean options are available if required, ask your MasterMix representative about these options.

Graco 2K automatic valve with static mixer

As an example a large manufacturer of electronic equipment requested a system that would meter precise volumes of encapsulate sealant, yet as there were several applications the volumes needed to be delivered at variable flow rates to allow product flow-out or settling. On top of these requirements the silicone to be used required constant agitation to avoid settling of the various additives.

As the shot size was also small we could not afford to introduce air to the system as to purge any entrapped air could throw the ratios out and waste a very expensive electronic device. To address this issue we incorporated low level warning alarms. Initially a warning light would flash, and if the supply container wasn’t refilled within a given number of shots an audible alarm would be set off. If this didn’t result in the feed system being refilled the system would then shut down and not operate until supply container levels had been replenished.

As the flow rates were small and stop start, the MasterMix needed to be extremely accurate and the flow of both fluids smooth and even to allowing the static mixers to achieve full mixing. January 2001 we delivered the system, went through the various stages of training the operators, management and service staff, set the volumes and the delivery rates as requested and this MasterMix MasterShot system has a service schedule in April 2003.

This variable ratio, variable volume shot

Inconsistent fluid flow and pressures can starve or spike the fluid pressure and will be seen as inconsistent mixing or metering at the mix manifold. As with all automatic systems the Proportioner will only perform if the conditions are stable.
Successful installations start with the adhesive supply container not with the applicator head.

Upon receipt of your request for quotation we will require a plan and elevation of the factory and proposed application site, then and only then will we look at the system layout starting with the supply container.

Adhesive feed systems are designed to supply resin and hardener to the MasterMix at the lowest possible pressure. Graco Husky pumps with their low cycle pressure are ideal for this application.