Ligne de production Henkel (adhésifs)

Explosion-Proof & High-Precision Batching Solution for Henkel (Adhesives) Production Line

Customer Background: Henkel is a global leader in the adhesives, sealants, and functional coatings industry. Their production facilities maintain world-class safety protocols, particularly in the handling of chemical powders and additives used in high-performance glue manufacturing. The process demands extreme precision to ensure chemical consistency and stringent adherence to explosion-proof standards.

1. Technical Challenges & Requirements

The project involved a complex raw material handling and batching system that integrated both bulk and micro-ingredients.

• Hazardous Environment Safety: Due to the combustible nature of certain chemical powders, the entire system required a robust Explosion-Proof (EX) design to mitigate the risk of dust explosions.

• Complex Material Handling: The system needed to manage two distinct input streams: major ingredients from bulk bags (ton bags) and micro-ingredients from manual feeding stations.

• High-Stakes Accuracy: Adhesive formulas are highly sensitive; even minor deviations in batching can compromise the bonding properties of the final product.

• Integrated Process Flow: A seamless transition was required between unloading, iron removal, screening, mixing, and final drum filling.

2. Doebritz Engineering Solution

Doebritz provided specialized ATEX-certified Rotary Valves and integrated pneumatic conveying components, serving as the technical core of the feeding and metering sections.

• Certified Explosion-Proof Design: Doebritz rotary valves were engineered to act as flame barriers. With high-strength housing and precision-engineered rotor clearances, these valves prevent flame propagation and pressure shocks in the event of an internal explosion, meeting Henkel’s rigorous safety standards.

• High-Precision Pneumatic Metering: For the major ingredients, Doebritz implemented a metering solution integrated with the bulk bag unloading station. The rotary valves ensure a stable, volumetric feed into the pneumatic conveying line, maintaining high dosing accuracy under positive pressure.

• Contamination & Quality Control: To ensure the purity of the adhesive, the system was integrated with high-efficiency magnetic separators and vibrating screens, all designed to operate within the pressurized, EX-rated environment.

3. Systematic Process Overview

1. Dual-Stream Feeding: * Major Ingredients: Discharged via a Bulk Bag Unloading Station and metered into the system.

2. Minor Ingredients: Introduced via a Manual Feeding Station equipped with dust collection.
3. Pneumatic Conveying: Both streams are transported via a pressurized pneumatic system, controlled by Doebritz rotary valves to maintain system pressure and feed consistency.
4. Purification: Materials pass through dedicated iron removal and screening stages to eliminate any foreign particles.
5. Homogenization: Ingredients enter the mixing phase where the adhesive formula is stabilized.
6. Automated Filling: The final product is precisely filled into drums/barrels, ready for distribution.

4. Results and Strategic Value

The partnership with Doebritz allowed Henkel to achieve a highly automated and secure production environment:

• Uncompromising Safety: The system operates in full compliance with international explosion-proof standards, protecting both personnel and assets.

• Formula Consistency: High-precision metering reduced batch-to-batch variability, ensuring the superior quality of Henkel’s adhesive products.

• Operational Efficiency: The integration of automated bulk handling and precise pneumatic conveying minimized material waste and optimized the production cycle.

• Proven Strength in Chemicals: This successful deployment reaffirms Doebritz’s expertise in delivering high-security, high-precision equipment for the most demanding chemical processing environments.