Integrating Liquid Handling Systems into Automated Processes

Automated liquid handling systems manage the precise movement and dispensing of liquids within agricultural and industrial processes. These systems range from simple automated dispensers to complex integrated solutions that control every aspect of liquid handling.

Dispensing Systems

Automated dispensing systems accurately measure and deliver specific volumes of liquid into production processes. One common example is the “Mother Tote” system, where liquids are transferred from a portable or removable tote into a stationary surge tank (the “Mother Tote”). This setup allows for continuous supply and precise dosing of liquids into mixers or other equipment. These totes are compatible with many chemicals and other materials; they can be heated to maintain adequate flow based on the liquid’s viscosity/temperature.

Liquid Processing Control Systems

These systems integrate multiple components to provide comprehensive control over liquid handling processes. They use Programmable Logic Controllers (PLCs), PCs, Human-Machine Interfaces (HMIs), and advanced control software to enable real-time monitoring and adjustments.

Key components include:

• Pumps: Various types, such as diaphragm, peristaltic, and gear pumps, are selected based on your application’s specific needs, ensuring accurate flow rates and pressure control.
• Valves: Solenoid valves, ball valves, and others are critical in directing the flow and controlling the start and stop of liquid movement within the system.
• Sensors and Meters: Devices measuring flow, level, temperature, and pressure provide essential data for maintaining optimal operating conditions.
• Tanks and Piping: Properly designed storage tanks and piping systems are essential for safe and efficient liquid storage and transfer.

Control Software and Data Management: Advanced software solutions allow for monitoring, controlling, and managing liquid handling processes.

Integrating liquid handling systems into your automated processes offers numerous advantages that can transform your industrial operations.

Improved Accuracy

Automation brings a high level of precision to your measurement and dispensing tasks. Automated systems reduce human error and variability inherent in manual processes. They deliver consistent and accurate liquid dosing. This precision is vital in industries where slight deviations affect product quality or safety.

Increased Efficiency

Automated liquid handling accelerates your processing and reduces cycle times. Streamlined workflows minimize the need for manual intervention. This efficiency boosts productivity and contributes to cost savings.

Waste Reduction

Automation minimizes over-dispensing and spillage by controlling liquid flow with exacting precision. Accurate dosing ensures that your resources are used effectively, reducing waste and lowering material costs.

Enhanced Safety

Automated systems decrease the need for your workers to handle hazardous liquids directly. Improved process control and monitoring further enhance safety by detecting issues promptly. Always review the manufacturer’s MSDS (Material Safety Data Sheet) before using, handling, or bringing liquid into your facility. Understand all liquid properties.

Improved Quality

Consistency in liquid handling leads to uniformity in your final product. Automation helps each batch meet the required specifications.

Transitioning to automated liquid handling requires careful planning and execution to maximize the benefits.

Assessment of Current Processes

Begin by evaluating your existing manual systems to identify inefficiencies and areas needing improvement. Consider factors such as the types of liquids you handle, desired flow rates, precision levels, and safety concerns (review MSDSs as previously mentioned).

Selecting the Right Automation Solution

Choosing the appropriate equipment is essential for successful automation. Selecting pumps, valves, and sensors that are suited to your application’s needs is required. For instance, peristaltic pumps may be ideal for gently handling sensitive liquids, while gear pumps might be better for high-viscosity fluids. Integration with your existing systems should also be considered, whether upgrading current equipment or incorporating new technologies. Ensure you select a supply partner with expertise in these component selections and overall control and automation expertise.

System Integration and Testing

Integrating automated liquid handling systems with your existing processes involves several steps:

• Design and Planning: Develop a comprehensive plan that outlines how the new system will interact with your current operations. Ensure a new or updated PID (Piping & Instrumentation Drawing) is developed and reflects the new automated system. Your supply automation system supply partner can assist you with this.
• Installation: Implement the hardware components, ensuring compatibility and proper configuration. Your automated system supply partner may be able to offer a turnkey installed solution or recommend qualified contractors for the installation and provide supervisory services to ensure the installation is properly executed.
• Testing and Calibration: Rigorously test the system to verify accuracy and reliability. Calibration confirms that measurements and dispensing meet your required specifications.

Training and Support

Equip your staff with the knowledge and skills to operate and maintain the new automated systems. Training programs should cover system operation, troubleshooting, and routine maintenance tasks.

The field of liquid handling automation continues to evolve with emerging technologies. Advances in sensors, pumps, and control systems enhance precision and reliability. Innovations in automation software and data analytics offer the potential for better process monitoring and optimization.

Sustainability is becoming increasingly important. There’s a growing trend toward energy-efficient liquid handling solutions that reduce environmental impact. This focus on sustainability benefits the planet and leads to improved process efficiency and cost savings.

With over 50 years of expertise in custom engineering solutions for liquid handling/dosing, dry material weighing and batching, and bulk material handling systems for a wide range of industrial and agricultural market segments, Sterling Systems & Controls proudly has the experience to provide you with expert guidance to achieve your automation and process improvement goals. Contact us today to discuss how our knowledge and expertise can align with your goals, and how you can continue your journey toward manufacturing excellence!