Introduction
Film-coating processes demand exceptional precision to ensure uniform thickness, adhesion, and visual quality of coated materials—whether for food packaging, or industrial films. Even minor inconsistencies in raw material mixing can lead to costly defects like uneven coatings, delamination, or rejected batches.
In this project showcase, we explore how HENGJU’s Gravimetric Blender was integrated into a film-coating production line to address these challenges, delivering measurable improvements in efficiency, quality, and cost savings.
The Challenge: Inefficiencies in Traditional Mixing Methods
A leading manufacturer of food-grade flexible packaging films faced recurring issues with their existing volumetric blending system:
Material Waste: Over 8% raw material loss due to inaccurate dosing of additives (e.g., anti-block agents, slip additives).
Quality Variability: Coating thickness fluctuations (±15%) caused by inconsistent mixing, leading to customer complaints.
Downtime: Frequent manual recalibration of volumetric feeders disrupted production schedules.
The company sought a solution to achieve sub-1% dosing accuracy, automate material handling, and integrate seamlessly with their high-speed film-coating machines.
Our Gravimetric Blender was customized for the client’s film-coating line, featuring:
Precision Weighing Technology:
Real-time load cells with ±0.5% accuracy for exact dosing of masterbatch, resins, and additives.
Automatic compensation for material density variations (critical for hygroscopic additives).
Smart Integration:
IoT-enabled interface synced with the film-coating machine’s PLC, enabling dynamic adjustments based on line speed (up to 450 m/min).
Contamination Prevention:
Closed-loop design with anti-static components to eliminate cross-contamination between batches.
Energy Efficiency:
Servo-driven motors reduced power consumption by 18% compared to traditional blenders.
Results: Quantifiable Impact on Film-Coating Performance
After 6 months of operation, the gravimetric blender delivered:
↓ 85% Material Waste: Precision dosing cut raw material losses to 1.2%, saving $220,000/year in additive costs.
↑ 25% Production Uptime: Automated calibration reduced manual interventions, enabling continuous 24/5 operation.
±3% Coating Uniformity: Thickness consistency met ASTM D4321 standards, eliminating batch rejections.
ROI in 10 Months: Total savings from waste reduction and productivity gains exceeded the blender’s upfront cost.
Technical Spotlight: Why Gravimetric Blending Outperforms Volumetric Systems
For film-coating applications, gravimetric technology provides 3 critical advantages:
Adaptive Mixing: Adjusts ratios in real-time based on feedback from inline thickness gauges.
Multi-Material Handling: Compatible with powders, pellets, and liquid additives (e.g., silicone-based slip agents).
Data Transparency: Cloud-based reporting tracks material usage, downtime causes, and maintenance alerts.
Industry Applications Beyond Packaging
The same gravimetric blending principles apply to:
Pharmaceutical Film Coating: Accurate API (active pharmaceutical ingredient) layering for controlled-release tablets.
Electronics: Uniform dielectric coatings for flexible circuits.
Solar Films: Precise dispersion of UV stabilizers in photovoltaic backsheets.
Conclusion: Future-Proofing Film-Coating Production
As industries demand thinner, higher-performance coatings, gravimetric blenders are becoming indispensable for achieving repeatable quality and sustainable manufacturing.
Ready to Transform Your Coating Line?
[Contact Us] today to request a free feasibility analysis or download our [Case Study: Gravimetric Blenders in Film-Coating Applications].
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