LIAD and Palziv North America: A Partnership in Tailor-Made Automation and Precision

In the manufacturing industry, suppliers of ancillary equipment are frequently tasked with more than just installing new machinery; they are often called upon to upgrade and enhance systems that have been in operation for years. This task presents unique challenges, demanding a delicate balance between integrating modern technology with an existing foundation while meeting a client’s evolving needs. Our upcoming project with Palziv North America, a prominent manufacturer of cross-linked polyethylene foam, is a perfect illustration of this dynamic in action.

Upgrading for a Specialized Process

Palziv North America has achieved considerable success in its roll department through the strategic implementation of automation. Now, their focus is on revitalizing their sheet department with a fully automated, state-of-the-art system. The core of this ambitious project is a highly sophisticated dosing system designed to prepare complex recipes of granules and powders for their kneader-based production process. This is where our expertise in creating client-specific solutions comes into play.

A Custom-Engineered Dosing Solution for a Kneader Process

This project involves a significant enhancement of a dosing system we installed a decade ago. The original system was designed to supply four main granular materials to the two kneaders. To handle more complex formulations, our custom-engineered upgrade expands this foundation by adding two completely new multi-component weighing systems that work in concert with the original.

The first new addition is a weighing system dedicated to six different granular additives. The six materials are dosed sequentially into a single weigh hopper to create a precise batch. The second addition is a weighing system for three powder material channels, which utilizes mechanics based on our proven Powder Save technology. In the fully automated process, the three separate systems—the upgraded original for the four main granules, the new one for the six additives, and the new powder system—prepare their respective batches in three independent weigh hoppers. Once weighed, the materials from all three hoppers are conveyed to the kneaders, assembling the complete, unmixed recipe just before the mixing process begins.

A weighing system dedicated to six different granular additives

The Benefits of Integrated AutomationBy designing a system that works in perfect concert with their kneader, we provide Palziv North America with a multitude of advantages that go beyond simple automation:

• Precise Dosing: Our system guarantees that every recipe is formulated with exacting accuracy before it ever reaches the kneader.
• Uniform Batches: The high level of precision ensures absolute consistency from one batch to the next, which is critical for final product quality.
• Consistent Cycle Times: Automation creates a predictable and steady production rhythm, optimizing the kneader’s efficiency.
• Hands-Free Operation: The fully automated batch preparation process eliminates manual intervention, reducing labor costs and minimizing the potential for human error.
• Comprehensive Production History: The new control system meticulously documents all production data, including component weights and batch details, creating an invaluable record for quality control and process analysis.

«The collaboration with LIAD has been a true partnership”, says Erez Ravid, Palziv NA Engineering Manager. “They worked closely with our engineering team to deeply understand and characterize our unique process needs, resulting in a custom-designed upgrade that is perfectly tailored to our kneader lines.»

We are confident that this tailor-made solution will be a resounding success, providing Palziv North America with a significant competitive advantage. This project is a prime example of how LIAD’s expertise can empower manufacturers to achieve new levels of efficiency, precision, and automation in their specific production environments.

A weighing system for three powder material channels