Ply-pack packaging machine officially launched the volumetric metering packaging machine based on the intelligent compensation algorithm. Through dynamic error analysis and real-time calibration technology, the liquid filling accuracy is improved to ±0.3%, which is suitable for high-viscosity liquid packaging scenarios such as edible oil, dairy products, and condiments, helping enterprises to reduce costs and increase efficiency.
In-depth analysis of the source of volumetric metering errors
The ply-pack technical team has summarized four core factors that affect the metering accuracy of packaging machines through industrial measurements and simulation modeling:
Temperature fluctuations: The thermal expansion of the metering chamber material causes the volume of the cavity to change. For every 10°C increase in temperature, the error of cast steel material increases by 0.04%;
Leakage deviation: The gap between the piston and the cavity produces a slip volume. When the viscosity decreases by 1 cP, the leakage error shifts positively by 0.1%~0.3%;
Viscosity adaptability: High-viscosity liquids (such as honey) increase flow resistance, resulting in insufficient filling of the metering chamber, with an error of up to 1.5%;
Flowmeter nonlinear error: The pulsation of the gear/wheel speed causes instantaneous flow fluctuations. The instantaneous error of traditional equipment can reach 0.65%.
Intelligent compensation algorithm: a breakthrough in error control technology
The ply-pack volumetric metering packaging machine is equipped with the self-developed Dynamic-Comp dynamic compensation system, which realizes closed-loop error control through multi-sensor fusion and machine learning:
Dynamic temperature compensation: The built-in PT1000 temperature sensor monitors the cavity deformation in real time, and automatically corrects the volume value in combination with the thermal expansion coefficient of the material, reducing the temperature drift error by 80%;
Leakage adaptive algorithm: The slip volume is predicted through the pressure-viscosity correlation model, and the piston stroke is adjusted with a response speed of 0.1 seconds. The leakage error is stabilized within ±0.05%;
Viscosity compensation model: Establish a fluid property database based on the Reynolds number, automatically match the filling speed and the opening and closing rhythm of the metering chamber, and adapt to 0.5~5000cP liquid. Technology upgrade highlights: packaging machine performance has evolved again
Modular design: supports rapid switching of three metering units: gear type, piston type, and scraper type, and the changeover time is shortened to 20 minutes; Intelligent calibration system: automatically performs no-load calibration and medium density detection before each batch of production, reducing manual intervention by 90%; Multi-sensor fusion: integrated pressure, temperature, and optical triple nucleation modules, the interception rate of defective products is increased to 99.8%. Application Case: Error Compensation Empowers Actual Production
After a leading grain and oil company adopted the ply-pack volumetric metering packaging machine:
5L edible oil filling line: The mass deviation of a single barrel was compressed from ±15g to ±5g, saving more than 2 million yuan in raw material costs annually;
1L high-end dairy product line: The filling efficiency reached 1,200 bottles/hour, and the bag breakage rate dropped from 0.5% to 0.02%;
500ml seasoning sauce production line: Through the viscosity adaptive mode, the same-line production of heterogeneous fluids such as bean paste and oyster sauce is achieved.
