Continuous Mixing and Filling of Viscous Materials

With the introduction of the new ViscoDUO-VM HD, ViscoTec has become a pioneer in the dosing of two-component fluids and pastes in the hygienic sector. The new dosing system offers continuous mixing and dosing of two low to high viscosity materials with the same or different viscosities and guarantees precise, repeatable and process-safe mixing in a validated process.

The VPHD hygienic dispenser for single-component materials has been part of the dosing technology specialist's portfolio since 2014. Numerous well-known customers have been impressed with the high quality of these product-friendly and high-precision dosing pumps based on the endless piston principle. The development of the ViscoDUO-VM HD was led by the demand for the same quality - but for two-component materials. Due to ever stricter regulations, especially in the field of medical technology, FDA-compliant materials for fluids in direct contact with the product are required from the initial project planning stage. This is even more so when the material to be dosed comes into contact with the human body during the application.

All components of the new ViscoDUO-VM HD meet GMP requirements and are FDA compliant. The dosing system can be used in the medical technology and cosmetics industries as well as in the diagnostics and dental industries. It can also be used for the production of food and household goods or home care products. The modular design of the ViscoDUO-VM HD with four different sizes on both sides, allows it to be used in a wide range of applications. Flow rates from 0.5 ml/min to over 1000 ml/min can be implemented. Like all products from the ViscoTec portfolio, the dispenser is easy to integrate into automated processes. Thanks to the built-in endless piston principle, dosing is completely pulsation-free. Both the mixing ratios - from 1:1 to 100:1 - and the flow rates are freely selectable. The filling quantity is individually adjustable. All components in contact with the product are made of stainless steel 1.4404 and can be issued with a batch certificate if required. The customer has a choice between different FDA-compliant elastomers for the optimum use in their application.

Application in medical technology

The ViscoDUO-VM HD is used in the mixing of two-component silicone to seal an artificial lung, for example. The patient's blood is pumped through the artificial lung. The silicone to be mixed is in direct contact with the product and must therefore be FDA compliant. Another example is the application of a two-component adhesive on plasters for the skin. The task of the dispenser is the precise and validated mixing of the adhesive (component A) with special ingredients (component B). For complete process reliability and repeatable dispensing results.

Application in the dental industry

In the dental industry, the dispenser is used in the production of ceramic teeth and ceramic inlays. Two-component ceramic slags, for example, are mixed and filled into teeth moulds. The newcomer to the ViscoTec portfolio is impressive with its long service life, even with abrasive materials, thanks to the proven endless piston principle.

Application in the cosmetics industry

Make-up must match the consumer's skin color perfectly. This creates production challenges since equipment must be flexible in order to produce a wide range of color tones. ViscoDUO-VM HD makes the process of mixing different color shades easy and efficient. To do this, the basic component is mixed with different amounts of colorant by simply adjusting the mixing ratios with the control system. The easy cleanability of the ViscoTec dispensers also allows quick and easy batch changes.

Application in home care products and food

In the continuous mixing and filling of detergent pods, the simple possibility of batch change is impressive, along with highly precise, repeatable dosing. The basic components of the pods are mixed with different colors. Thanks to the optional rinsing connection (CIP connection), a quick color change during production is possible. The same applies to the decoration of cookies, gingerbread and pastries. Here, icing sugar is mixed with a wide variety of colors and then dosed with precision. Waiting times are minimized, and thanks to fast cleaning, smooth and flexible production is guaranteed.

The trend towards continuous manufacturing

In the field of hygienic applications, the trend is focusing on continuous manufacturing. At present, two components are usually stirred in batches in a container and then transferred further. In continuous manufacturing, batch production is replaced by a continuous flow. The ViscoDUO-VM HD dosing system from ViscoTec, for example, then takes over the exact mixing of the materials.

This is where the advantages of the endless piston principle become clear: an endless dosing, with the necessary changes in delivery rate being controlled one to one via the speed of the dispenser. A continuous adjustment of the mixing ratios is also possible by controlling the individual dosing pumps A and B. This improves the process time and simplifies monitoring - cleaning the containers with agitator is no longer necessary, as the ViscoDUO-VM HD can also be cleaned via CIP. (See diagram "Continuous Manufacturing")

The ViscoDUO-VM HD will be presented for the first time at the Pharmakongress trade fair in Düsseldorf (March 2020) and at the Interphex trade fair in New York (April 2020).