The KDA InLine Dispense System

KDA do not use fixed tank storage areas-we prefer to use the suppliers delivery containers-

 

  

The storage area is arranged according to customer needs.

 

The storage area can be quite small, typically it will be 12-15 metres long and 1.5 meteres wide.

 

The system uses an air operated pump and positive displacement mechanical flow meter and

delivers the chemical direct into the process machine:

 

 

   

 

In the simplest mode of operation the KDA InLine system is operated by the same barcoded job sheet which is used for the KDA barcode dye weighing system:

 

                                          

 

The InLine system can also be operated by the dyeing machine control PLC or by an external computer system by a network

 

 

Comparison of KDA vs Other systems

Flow Meter : -   Mechanical, no complex electronics – the principle of operation is easily understood. (See Macnaught Industries website)       Positive displacement with a fixed size chamber, needs no calibration, can cope with change of product being dispensed.   Easily serviced and repaired by factory personnel, complete overhaul in 10 mins by factory personnel.	Complex electronics using various principles – coriolis effect/ultrasonics/magnetic flux. Ultasonic flow meters do not work at all with viscous chemicals because viscous chemicals do not flow at a constant velocity across the pipe diameter.   Only functions correctly when full of the liquid being dispensed, uncertain during change over between chemicals and water.   Requires service from manufacturer/agent
Storage Area:-   Operates directly from supplied chemical containers.         Easy to ensure that the new chemical container is the same as the as the one being used.     Easy change over from one product to another. Simply replace container with new product.	Requires dedicated tank storage with expensive-to-operate refill system and wastage of time and chemicals during refilling and then cleaning of refill system   There is a possibility to refill a tank with the wrong chemical – with disastrous results.     Tank will require to be emptied and cleaned before refilling with new chemical.
Mechanical and Maintenance Issues:
The KDA system uses commercially available T port valves. Simple with proven reliability.       The ARO pump is a simple reliable air operated diaphragm pump. The whole unit can be replaced by a mechanic in under 5 minutes with a 13mm ring spanner – no pipe disconnection is needed.   The whole system is controlled by a single industrial PC, there are no PLC’s and no complex interfaces between control PC’s and PLC’s   The electronics are all commercially available – there are no special custom made electronic components.	Various complex mechanical arrangement are used – some even use semi robotics !!! The Color Service system is very complex and leaks badly because of complex connectors   Most use gear pumps with inverter drives, problems are usually difficult to solve. Pump replacement is difficult     All use PLCs with the attendant complexity, they are specific to one type of PLC, this is often of the manufacturer’s own design.   Most use custom components to ensure that the support (expensive!) must come from the manufacturer.

The InLine system is also widely used to prepare mixes for pad finishing machines and preparation machines such as continuous bleach ranges and singing machines. Information about these applications is available on request.

 

★ There are likely to be dye houses which have a random layout of machines or have no space at all available for the

KDA InLine dispense system.

 

For these there is still a way to take advantage of the level of control given by automatic dispensing systems.

 

The KDA Gravimetric Dispense System

A central dispense head - which may be located in a separate room or in the dyehouse:

It consists of up to 20 air operated dispense valves mounted over a high resolution electronic weighing scale.

The whole unit is controlled by an industrial PC and commercially available output cards.

The operator reads the bar code on the job sheet.

The dispense will NOT start unless there is a container on the scale.

There is a simple colour graphic to show the progress – if the operator removes the container before the dispense is complete he is told to replace it.

After the container has been removed the dispense head is washed automatically.

The scale is covered by a tilting platform to assist with wash water drainage