Automated IBC filling with SysTec controller

SysTec Systemtechnik und Industrieautomation GmbH (Germany) – 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.

The process:

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.

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

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

Watch the video.