Ambitious projects require innovative solutions.

FÜLL consults and supports you from the idea to the turn-key-plant.




Due to the high quality nature of the here present pictures, longer loading times may occur.

 Make Do and Mend – Retrofit

“Retrofit” or “Revamp” is modernization of plants and systems as a cost-effective alternative to a new constructed system. Often only a few aspects of FÜLL systems require improvement after a long operating life. Like for new systems, the plant safety is the outmost important thing to keep in mind.

For this reason, FÜLL offers modernizations individually and consults with all decisions to make. The final degree of modernization will be defined together with the customer.

The following will give an insight to the possibilities, that can be executed.

Electric control

The centerpiece of the electric control is the computer, which saves all important system parameters as well as administrating formulations, job data and protocols. But also a computer in industrial quality is aging and should be replaced and its software updated.

The development in automation goes forward in a speedy manner and the trend towards ethernet communication is naturally part of the current controls offered by FÜLL. New possibilities for remote maintenance via internet and a secure VPN tunnel (Virtual Private Network) are associated. On this way FÜLL service personnel can analyse problems down to the PLC (Programmable Logic Controller) and render assistance.

Valve actuation

The valves used in the dispensing centers FS 182.2 and FS 2005.2 series are controlled by servo drives. They guarantee a highly dynamic and precise dispensing process. The exact valve opening allows for optimal adjustment of the dispensing parameters or rather allow the system to determine and optimize the parameters automatically by the dispensing software CALIPSOPRO.

Those new drives supersede inconvenient initialisations after power fail restarts.

Valve actuator

The valve actuator is the frequently used construction group in the dispensing center, because all valves are opened and closed continously. A fast and precise stroking is essential, because not only the operning and closing speeds are relevant, but also the compliance with the correct stroke for coarse and fine dispensing are critical.

Valve platform

The dispensing valves in the most gravimetric dispensing centers are installed on a valve platform, which is actually a powered sledge for positioning the currently required valve under the valve actuator. the platforms servo drive is of the same type as the the one used for the valve actuation, simplifying spare part inventoring.

A fast and precise positioning at a speed of generally 250 mm/s reduces dispensing times considerably. This drive also keeps its current position “in mind” after a power fail restart. This significantly simplifies system restarts after emergency stops or maintenance, too.

Valve cleaning unit

The modernization or conversion with an automatic valve cleaning unit is naturally also a retrofit solution. The valve cleaning unit is the perfect upgrade for the dispensing center, when it is not possible to manage manual cleaning the valve heads during production peaks. It’s a reliable protection against dirt and migration of adherent substances. It also frees extra capacities, because it safes a lot of time for the operator.

The closed valve cleaning systems combines chemical with mechanical cleaning. The valve heads are cleaned with a product-compatible cleansing agent by rotating brushes. The cleansing agent is used in circulation to reduce consumption.

At an already used valve cleaning unit, the wear parts like brushes and hoses are inspected after long time use.

Wear parts

Nevertheless sealings and hoses are exposed to chemical and mechanical stress and therefore to be seen as the main wear parts in every system. A cracked hose can disrupt production for hours and wastes personnel resources. These kind of wear induced problems can be better seen by externel personnel, wich is not working every day at the particular system.

Naturally FÜLL Systembau GmbH only uses high-quality hoses, to reduce maintenance.

Therefore our remark:

FÜLL offers maintenance contracts for dispensing and storage systems.

Safety

Operators safety is the highest priority to FÜLL. All changes and enhancements are made according to the newest standards being effective.

But FÜLL never loses track for the main objective – the cost-effective modernization. Sometimes it is more cost-effective to easily exchange construction groups, because complex modifications imposed by technical supervising institutions may be higher in price.

FÜLL systems follow a consequent systematic design to allow for both possibilities.

Gladly FÜLL evaluates the safety of your system, makes recommendations and consults for a suitable solution.

Worth knowing / Machines from other manufacturers

Naturally FÜLL Systembau GmbH offers retrofit solutions for third-party products, also.

This way the familiar system design can be sustained and the high-quality FÜLL technics optimally prepare the production for the future.

 FÜLL on exhibition – 11th September 2012 ProFlex

This year again, FÜLL Systembau GmbH is represented at the DFTA symposium and will show dispensing technic at the ProFlex.

Our sales team will gladly inform you about the FÜLL systems.

  • ProFlex Stuttgart
  • 11. – 12. September 2012
  • ProFlex Stuttgart
  • September 11th – 12th, 2012

 FÜLL on exhibition – 12th March 2012 INTERLAKOKRASKA

  • INTERLAKOKRASKA Moscow
  • Expo Center
  • GERMAN PAVILION
  • Pavilion 1
  • Booth 1 D41
  • March 12th – March 15th, 2012
  • Rrepresented by Holliday Instruments
  • Joint booth with D.W. Renzmann

 It is always the same! – The reproducibility

“Reproducibility -

The closeness of agreement between independent results obtained with the same method on identical test material but under different conditions (different operators, different apparatus, different laboratories and/or after different intervals of time. […]“
Compendium of Chemical Terminology: IUPAC recommendations, 2nd Edition, Blackwell Science, 1997

What impact has reproducibility on your production?

In a production process nothing is more important than consistant quality.

In the paint- and flexible packaging industry, colors have to be in specific constraints in the color space. Viscosity has to meet defined values to guarantee the production of an ideal application. The perfume industry requires identical combinations of the scent profile, the fragrance intensity and effect in every perfume bottle.
This list could be easily extended. All examples, however, have one aspect in common: consistant quality, which is only achievable by means of reproducible dispensing.

How to maintain a consistant product quality?

Proper storage technology

Storage systems

When a liquid product tends to sediment, to separate in phases or when it is thixotropic or shear-thickening, homogenization in the storage container is usually required. This can be attained by a specially designed agitator and interval-controlled recirculation. Only homogenous liquid products will result in consistant quality and reproducible dispensing.

Product contacting parts

Only correctly chosen product-contacting materials can prevent corrosion. Together with the customer, FÜLL chooses the proper materials for storage, pumping devices, etc. to ensure the elimination of such problems. This guarantees a trouble-free production.
 
 

Precision dispensing

Gravimetrische Dosieranlagen

Due to many years of experience in handling sensitive products, concentrates, solvents and many more FÜLL is capable of dispensing any liquids with highest reproducible accuracies. It is possible to monitor the dispensed amounts for every operation at the on-site terminal. The dispensing protocol ensures a complete traceability of all target values and actual dispensed amounts, dispense times as well as individual accuracies.

What makes dispensing by FÜLL special?

During the design and construction processes, FÜLL considers the complex interaction between dispensing pump, dispensing valve, piping dimensions, fittings, the measuring instrument and the control and dispensing software with the fluid characteristics.

That is very important, because a high precision scale can only display its strength when the smallest dispensable amount is within the scale’s repeatability. Especially the continuously adjustable dispensing valves with integrated precision dosing needle constructed by FÜLL guarantees highest reproducible accuracies.

  До свидания! – FÜLL systems on their way to Moscow

After a few weeks of planning and construction the new system FS-XS left the FÜLL site in Idstein and sets off, well packaged, for Russia. Once there, it will dispense concentrated printing inks (masterbatches) and solvents in a high-precision manner (± 1 g reproduceability, depending on physical and chemical properties) as well as including residual inks with the dispensing software CALIPSOPro. This takes place via an interface, programmed by FÜLL, to a colorimeter provided by the customer.

A roller-conveyer and a single-post agitator are part of the shipment, because the optimization of the overall process is clearly one of the vital FÜLL-strengths. The process starts with delivery and storage of the raw materials and it continues with the fully automated dispensing and adjacent homogenization of the dispensing batches. The process ends with transport, packaging and finally application. The whole system runs flawlessly, only when the existing processes are taken into account for the new concept.

NextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnailNextGen ScrollGallery thumbnail
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS
FS XS

More and more companies in Russia appreciate FÜLL, the german quality standard, especially because only few plant manufacturers are able to produce systems, fulfilling the Russian safety standards.

For FÜLL it is not a real challenge, because after numerous successfully commissioned plants in Russia and more than 2.200 plants worldwide FÜLL understands to adapt to the on-site conditions like import rules and technical rules for construction and operation.

The special requirements for constructing plants for operation in Russia are the customs regulation and operating conditions.

Here are a few short notes regarding the new FS-XS

  • For 24 components (alternatively 16, 18, 32, 36 or the next construction series) – Qualified for your branch also
  • Documentation
  • Software
    • Storage and order administration –with interface to your ERP on request
    • In national language on request
    • o Since decades programmed by FÜLL and continuously adapted and redesigned to the evolving demands of our customers
  • Parameterization and design
      Every components has its very own set of parameters, covering the physical and chemical properties. This way the dispensing speeds up significantly and a high precision dispensing result, also for the critical compounds, can be achieved – If nothing else because every dispensing valve, piping and fittings are sized to fit your products.
  • Precision dispensing valve
      The core pieces of any dispensing plant are the dispensing valves. Naturally only the FÜLL special dispensing valves are used.
  • Made from stainless steel – Quality that you simply need for industrial application
  • Explosion proof design – Operating terminal and control cabinet for hazardous areas (Zone 1)
  • Storage system – tank farm, barrel storage, recharging system, piping and the necessary electrics designed and produced by FÜLL
  • Earthing control – The earthing control unit checks whether the dispensing batch is connected to the equipotential bonding. If not, the unit denies a dispensing into the not earthed batch.