Dosing system

An ink dispensing system keeps track of every batch when every dosing step is stored with the number of the raw material batch used and reported back to the ERP system. At Epple Druckfarben, the weighing system enforces the entry of correct batch numbers, which rules out missing or incorrect entries. Batch splits across multiple containers are recorded as well. Material combinations can then be traced back to the original raw material batch without searching through documents.

Manual and automatic weighing can be combined in a central weighing system with a uniform user interface. Epple integrated its fully automatic dosing systems and six manual and semi-automated stations based on the Kalisto software. The system takes values from automatic dosing directly from the controller, while manual steps are recorded with guidance. Because all stations work the same way, employees can switch freely and continue orders at any workstation.

The dosing control system of an older plant can be replaced by software that manages orders and recipes and stays in sync with the PLC. In one Innomat example, a Kalisto-based solution replaced an ageing Dosaumat. It manages orders, recipes and container data in an SQL database and talks to Siemens controllers via encrypted OPC UA. Synchronisation with the PLC keeps component stock up to date. Exports to PDF or Excel allow further analysis.

A batch weighing system reports dosing orders back via an interface that passes orders from the ERP system to the controller and reports results. On the Asprotec plant of a security ink manufacturer, the order is entered directly in SAP; the controller carries out the dosing and reports the order back, including the batch numbers of the raw materials. At Epple, Microsoft Dynamics 365 Business Central transfers orders via a REST interface, and a local buffer bridges connection losses.