Dosage System TOP 7000 Cast: Precision and Stability for Casting Processes

As a production solution for changing materials, small batch sizes, and high quality requirements, the new TOP 7000 Cast sets a clear standard for efficient, stable, and reproducible dosing processes in the casting environment. © Elmet

His new precision dosing system TOP 7000 with the addition "Cast" has been specially developed by Elmet to meet the requirements of casting, coating, and manual molding applications. It is suitable for processing from 20- or 200-liter containers and is characterized by its particularly high precision and process stability. With this, Elmet expands its product range of dosing systems with an independent solution for applications outside of traditional LSR injection molding, for which the systems TOP 700, TOP 3100, TOP 5100, and the flagship TOP 7000 Pro are designed. Elmet is presenting the new dosing system TOP 7000 Cast to the public for the first time at MD&M West in Anaheim, California/USA.

Constant volume flow, stable mixing ratio, reproducible results

The system, specially developed for casting applications, is based on Elmet's high-performance type TOP 7000 Pro and combines a constant volume flow with a stable mixing ratio. This enables reproducible component quality, even with materials with highly variable viscosity and fillers. Up to five freely configurable ramp profiles ensure precise and process-safe filling processes. Freely selectable shutdown criteria, such as time, volume, filling pressure, or an external start/stop signal, allow flexible adaptation to different casting processes. Optionally, stored recipes can be called up within seconds via QR code recipe management. This saves time and prevents incorrect settings. Additionally, up to six additives can be mixed into the optimally blended base material with an accuracy of +/- 0.01%.

The container change, possible from three sides, occurs fully automatically from the container rim. It takes less than five minutes for a pair of 200-liter containers, enabling a quick restart. The fully automatic venting ensures constant process conditions with each change. The intuitive software and self-learning control system, which automatically adapts to the material's feeding behavior, reduce operating effort and increase process safety. Feed rates of – depending on viscosity – more than five liters per minute allow for short cycle times. In combination with material utilization of up to 99.8% per container, low power consumption of only 150 to 400 Wh during operation, and low maintenance costs, this results in high cost-effectiveness over the entire lifespan of often twenty years or more.

The TOP 7000 Cast complies with the requirements of EN ISO 13849-1 and is CE, RoHS, and UL compliant. It is designed for all standard materials, flame-retardant materials, HVI materials, oil-resistant compounds, medical materials, as well as other special materials. The processable viscosity range extends from 0.001 Pa·s to 3,000 Pa·s. An optional wear-resistant version is available for highly filled and abrasive materials, designed for continuous operation without increased maintenance intervals.

For a wide range of industrial applications

Typical applications of the TOP 7000 Cast, which place high demands on precision, material homogeneity, and reproducible filling processes, include direct filling (casting) of products for high- and medium-voltage areas such as insulators (HVI) and composite hollow-core insulators, as well as cable joints. Other applications include manual molding of medical products such as manifolds (fluid and gas distributors), prosthesis liners, and medical cushions (orthopedic pillows), optionally with or without dispensing gun. In the areas of fabric and paper release coating, as well as cable sheathing, where uniform, controlled material application is required, the TOP 7000 Cast scores with its continuous, stable volume flow, even with significant viscosity differences.