A new era for Moretto DGM Gravix dosing units: Innovation serving the plastics industry

The transformation of plastic polymers involves a complex process with multiple steps to achieve a high-quality product from mechanical, aesthetic, and functional perspectives. One of the most critical stages is dosing, where the accurate blending of various raw materials, polymers, and additives is crucial.

The integration of advanced technologies and intelligent dosing solutions plays a key role in optimizing the production process, enabling higher levels of efficiency and quality. The use of sophisticated dosing systems contributes significantly to the overall success of the plastics industry, ensuring the production of finished products that meet high-quality and performance standards. In this context, the synergy between speed and precision in component mixing is essential to ensure an optimal result from both a technical and aesthetic point of view, while simultaneously minimizing production waste.

Moretto offers a wide and complete range of dosing solutions that includes volumetric and gravimetric dosing units. Within the gravimetric category, DGM Gravix stands out, currently undergoing a new phase of development marked by significant innovations that elevate precision and versatility standards to new heights. These innovations are geared towards ensuring even more precise and reliable dosing performance, reinforcing Moretto's constant commitment to delivering solutions that strive for excellence in the plastics industry.

DGM Gravix is a gravimetric batch blender designed to blend plastic granules directly on the IMM for optimal efficiency. The high level of technology, combined with its quality performance, has enabled DGM Gravix to perfectly meet the needs of processors, with over 10,000 units sold since its launch on the market.

Dosing represents a fundamental phase in preparing mixtures comprising 3 to 6 components, with the primary goal of achieving a consistently high-quality final product. Throughout this process, it is essential to carefully manage various phenomena. Typically, one or two base materials are employed, alongside a colorant referred to as a masterbatch, serving an aesthetic function for the product. In addition to this, additives may be introduced, often in minor percentages, sometimes as low as a few grams.
During this process, a crucial element is weighing, which is carried out by load cells that detect and manage the constancy of dosing. However, the signal from the weighing cells is often subject to disturbances caused by vibrations, which can come from various sources. These vibrations interfere with the frequency generated by the weight sine wave, introducing random peaks that complicate signal interpretation.

Utilizing advanced signal analysis and filtering algorithms is essential for maintaining stability in weighing accuracy management, leveraging the capabilities of digital technology. This approach ensures consistent dosing accuracy, within a few grams, even over extended production periods. In developing these algorithms, the company's Research and Development department incorporated state-of-the-art software that harnesses the power of artificial intelligence (AI).

At the heart of the restyling

Recently, Moretto has made significant improvements to DGM Gravix by introducing technical solutions, in order to optimize its use and increase its performance thanks to the development of digitalization. These changes reinforce the quality of the product, ensuring extreme reliability.

The hopper design has been completely renewed to guarantee a regular granule flow, ensuring a constant dosing accuracy. This feature translates into greater operational reliability and the ability to maintain very high standards of accuracy.

The electrical cabinet has undergone meticulous design to enhance the ergonomics, engineering, and accessibility of control devices. Positioned strategically at the rear, it provides convenient access to all essential machine components, including electronics, weighing cells, and pneumatics.

The user interface has been upgraded with the introduction of a new 7-inch touch view, featuring an articulated arm that optimizes ergonomics during use. Visual communication is facilitated by a set of LEDs, illuminated in four distinct colours, clearly indicating the operational status of the machine.

An exclusive element of the DGM Gravix remain the dosing eyelids, which ensure a high dosing standard thanks to an extremely fast reaction time, comparable to that of a blink of an eye. They maintain their reliability and durability well beyond 32 million operations. This stability is unique in the industry and essential for the consistency of dosing operations.

The weighing hopper, situated within the doser body, is devoid of mechanical constraints and connections to compressed air hoses and pneumatic cylinders, representing a notable design feature. This design ensures weighing without external disturbances, providing highly accuracy actual values. Coupled with digital technology, it enables the machine to operate seamlessly even under extreme conditions.

In addition, the algorithm operating on the Vibration Immunity System (VIS) overcomes the vibration challenge, allowing the installation of the blender directly on the processing machine, not only on top of an injection moulding machine, but also on a blow moulding machine, without any accuracy problems. This provides unprecedented flexibility by integrating the blender into the production environment.

There are dozens of success stories in the replacement of competitors' machines thanks to the use of Moretto's DGM Gravix blenders. Their performance leaves no doubt, proving their effectiveness even in the most demanding situations.

The mixing system has been further improved to optimize the uniform distribution of colorant and additives in microdosing. This includes the recent introduction of the DGM 20 version in the range, specifically designed for microdosing. This model finds its ideal application in the medical sector, where precision and reliability are key requirements to meet the high standards demanded.

With 9 different models and a remarkable 76 options, the DGM Gravix series establishes itself as the optimal choice for professionals in the plastics industry. A broad range caters to every need, ensuring high-level performance and versatility.

Evolving performance

The teach-in function also makes easy the installation of Gravix series directly on top of the processing machine. The programmable and recordable sequence of the hoppers for each recipe adds unique flexibility to adapt to changing production requirements with both injection moulding machines and other machines such as a bottle blowing machine.

The smart management gives the possibility to program up to 200 recipes, offering unprecedented versatility. The regrind management, with automatic master compensation, demonstrates attention to detail and sustainability.

Gravix DGM blenders not only guarantee measurement accuracy, but also offer a complete view of the operation with mixture and individual component totalisers, a timed mixer to avoid unwanted de-mixing, and a 7-inch capacitive touch interface with icon-based programming for simple and intuitive system management.

The advanced connectivity, with Ethernet and RS485 port for Modbus protocol and OPC UA connection as well as the readiness for the MOWIS supervisory system, fully developed by Moretto, makes the DGM Gravix blenders complete tools ready for the dynamic challenges of the modern plastics industry. Furthermore, compatibility with Moretto's EXA conveying system, capable of handling up to six receivers, underlines their commitment to seamless integration into every aspect of the production process.
In conclusion, Moretto's DGM Gravix gravimetric blenders represent a significant evolution in the world of plastics dosing, embodying the very essence of innovation and reliability. They are the undisputed choice for those looking for excellence in the blending of plastic granules, offering advanced performance to meet the most demanding requirements of professionals in the sector.