The Impact of Automated Dispensing Systems in Modern Manufacturing

May 2024

Automated dispensing systems in the manufacturing industry represent a crucial technological advancement, offering significant improvements in production efficiency, material usage, and quality control. As manufacturers seek to optimise their operations and minimise human error, these systems are becoming an integral part of modern manufacturing environments. In this article, we explore the role of automated dispensing in manufacturing, its various applications, the technologies that power it, the benefits it brings, and the challenges it presents.

Overview of Automated Dispensing in Manufacturing

Automated dispensing in manufacturing can involve the use of robotic systems and sophisticated software to precisely measure and deliver materials needed in the production process. This can include the application of adhesives, coatings, sealants, and other chemicals essential to the assembly of products. The precision and repeatability of automated dispensing systems ensure that the exact amount of material is applied consistently, reducing waste and ensuring that products meet strict quality standards. Dispensing applications can involve high to low-viscosity liquids and materials, and due to the vast spectrum of materials that can be dispensed, the selection of the correct dispensing equipment is crucial.

Key Technologies and Components

The core of an automated dispensing system in the manufacturing sector includes several key components. At the heart lies the dispensing mechanism, which often involves robotic arms equipped with pumps or extruders designed to handle various materials. These mechanisms are controlled by advanced software that dictates the amount, rate, and pattern of material application.

Control systems are another critical aspect. They incorporate sensors and feedback loops to adjust the dispensing process in real-time, ensuring accuracy and adapting to any variations in production conditions. This feedback loop can either be by dead reckoning using the dispense pumps or by physically weighing the volume dispensed while the product is being filled. Material Storage units within these systems can be environmentally controlled. Storage units within these systems are designed to keep materials at optimal conditions, helping to maintain their quality and usability.

The user interface of these systems is designed to be intuitive, allowing operators to easily set parameters, make adjustments, and monitor the entire dispensing process. This ease of use is crucial in maintaining efficiency and productivity in fast-paced manufacturing environments.

Applications in Manufacturing

Automated dispensing systems are utilised across a broad spectrum of manufacturing sectors. In the automotive industry, for example, they apply adhesives that bond vehicle parts together, such as in door panels and windshields. Electronics manufacturers rely on these systems to apply thermal pastes and other materials that aid in heat dissipation and adhesives that secure components in place on circuit boards.

In the aerospace industry, precision and reliability are paramount, and automated dispensing systems are employed to apply sealants and adhesives that must withstand extreme conditions. These applications demonstrate the system’s ability to handle a variety of materials and their adaptability to different manufacturing needs.

For accurate dispensing of liquids within the pharmaceutical and medical industries, dispensing systems such as servo-driven syringe pumps offer unparalleled accuracies of 0.5% of dispensed volume. They operate by using the servo system to aspirate (draw up the liquid) and dispense (blow out the liquid), with the system having the ability to ensure no air bubbles within the fluid or, indeed, no frothing takes place. Both scenarios can lead to quality issues and are crucial parameters in industries such as contact lens manufacturing.

Benefits of Automated Dispensing

The primary benefit of automated dispensing systems is their ability to enhance production efficiency. By automating tasks traditionally performed by hand, manufacturers can speed up the production process and reduce labour costs. This allows for employees to be upskilled into more rewarding roles. The precision of automated systems significantly reduces material waste, a critical factor when dealing with expensive materials like speciality adhesives or chemicals.

Quality assurance is another significant advantage. Automated systems provide consistent results, reducing the variability found in manual processes and ensuring that every product meets the same high standards. This consistency is vital in industries where quality control is tightly regulated, such as automotive and aerospace manufacturing.

Challenges and Considerations

Despite their many benefits, automated dispensing systems also present several challenges. The initial cost of implementing these systems can be high, requiring significant upfront investment in both equipment and integration into existing production lines. Additionally, these systems must be maintained regularly to perform optimally, which can add to operational costs.

Another challenge is the need for specialised training for staff who operate and maintain these systems. As technology advances, the complexity of automated dispensing systems can increase, necessitating continuous education and training programs for employees. However, the ROI is extremely fast and the benefits outway the cost and time invested at the beginning.

Given the complex nature of dispensing, it is very important that a specialised dispense company is partnered with to allow external trials of equipment so that the deepening equipment can be correctly selected.

It may sound obvious, but many dispensing applications are driven by the products themselves. For example, dispensing liquids such as mercury and acids requires pumps designed to withstand the possible erosion caused by such liquids. In some cases, ceramic pumps are used to overcome hazardous conditions, and stainless steel is also used.

Dispensing is not just for “wet” materials, with powder dispensing also requiring accurate dispensing. Again there is specialised equipment used in such applications and may utilise augers or screw feed systems to drive volumes of the material into the process, or volumetric, which uses a known volume to create a known dispense size, used in areas such as pill or pellets manufacturing.

Conclusion

As the manufacturing industry continues to evolve, automated dispensing systems play a pivotal role in enhancing production capabilities. While challenges such as cost and complexity exist, the long-term benefits of improved efficiency, reduced waste, and enhanced product quality make these systems a valuable investment. As technology progresses, we can expect these systems to become even more sophisticated, further integrating with other aspects of smart manufacturing to create more agile and responsive production environments. The future of manufacturing will increasingly rely on such advanced technologies to meet the growing demands of quality, efficiency, and sustainability.

Over the years, SP Automation & Robotics has been involved in many dispense systems for a myriad of materials, including adhesives, corrosive liquids, and also crystallised materials and powders in the pharma and munition industries. Although using completely different dispensing equipment, the same goal was achieved i.e. higher accuracy, improved quality, and higher throughput.

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