Introduction To Industry Scenarios
The production core of daily chemical light industry is viscous/paste/lotion medium, high alkali/weak acid, more foam, complex formula, frequent switching of SKU batches, high hygiene requirements, narrow production line space and 24-hour continuous production.
Typical measuring points:
Raw material storage: surfactant/essence/grease tank level, paste raw material tank level
Emulsification mixing: emulsification tank liquid level/pressure, reaction kettle temperature/pressure, mixing tank liquid level
Mixing and blending: mixing tank level/pressure, buffer tank level, pH adjustment tank level
Filling and packaging: filling machine material cylinder pressure, hose/bottling machine pressure, conveying pipeline pressure
Public works: Process water/purified water tank
Adapt to Core Products
QDY30A Household Hygiene Input Type Liquid Level Transmitter (316L+PTFE, Acid and Alkali Resistant, Anti Adhesive) Ra≤0.8μm、IP68、 Foam filtration)
QDY60 Series Paste/lotion Special Static Pressure Liquid Level Transmitter (flat film, anti blocking, anti high viscosity medium (10000MPa · s), temperature compensation)
QDW90A-3051 daily chemical hygiene flange liquid level transmitter (quick installation chuck, flat diaphragm anti scaling, special for emulsification tank/reaction kettle, easy to disassemble and clean)
QDKG anti-corrosion intelligent pressure switch/transmitter for daily chemical products (0.075 grade, 316L/Hastelloy, flat film, high alkali resistance, vibration resistance, emulsification/filling specific)
GLG daily chemical workshop anti-interference signal isolator/RS485 (2500V isolation, anti frequency converter/mixer interference, long-distance transmission in narrow spaces)
S803/SS803 Compact Digital Display Instrument for Daily Chemical (IP65, compact size, 316 shell, local alarm, narrow production line wall mounted)
Product Function
QDY30A/QDY60+QDW90A-3051 liquid level category (emulsion tank/raw material tank/blending tank)
Emulsion tank (essence liquid/cream/shampoo) liquid level: level film, anti adhesion, acid and alkali resistance, accurately control the oil/water phase liquid level ratio, ensure accurate formula, consistent batch composition, good product stability, and reduce layering/sedimentation defects.
Liquid level of raw material storage tank (surfactant/essence): 316L+PTFE, high alkali resistant, anti foam, real-time monitoring of liquid level, linkage of feed pump, prevention of overflow/empty tank, optimization of inventory management, and reduction of raw material consumption.
Liquid level of paste raw material tank: anti high viscosity, temperature compensation, stable monitoring of paste liquid level to prevent blockage, ensure uniform discharge, and improve filling efficiency.
Purified water/process water tank level: sanitary grade, long-term stability, ensuring stable production water supply, preventing water outages and shutdowns, and reducing energy consumption.
QDKG daily chemical specific pressure switch/transmitter (emulsification/filling/pipe network)
Emulsification tank pressure: acid and alkali resistant, vibration resistant, high-precision, controlling emulsification pressure (0.2-0.5MPa) to ensure sufficient emulsification, fine particles, improve product skin feel/texture, and reduce particle defects.
Filling machine material cylinder pressure: fast and stable response, precise control of filling pressure, ensuring consistent weight of each bottle/bag, reducing errors (± 0.3%), improving yield rate, and reducing material waste.
Reactor/mixing tank pressure: Micro pressure type, sanitary grade, monitoring the pressure inside the tank to prevent overpressure explosion, ensure reaction safety, and improve production stability.
Steam/compressed air pipeline network pressure: temperature resistant, long-term stable pressure, ensuring the stability of heating/pneumatic valves, and preventing process control caused by insufficient pressure.
GLG daily chemical workshop isolator (strong interference/narrow space)
Interference from frequency converters/mixers in daily chemical workshops: 2500V isolation, common mode rejection ≥ 60dB, suppression of peak interference, stable signal without jumping, no false alarms/shutdowns, ensuring continuous production for Anhui Qidian Automation Technology Co., Ltd.
Narrow production line long-distance transmission: RS485+Modbus, signal attenuation free, saving wiring space, real-time data upload to the central control, meeting the requirements of intelligent manufacturing for daily chemical products. Anhui Qidian Automation Technology Co., Ltd.
S803/SS803 Compact Digital Display Instrument (Local/Narrow Production Line)
Narrow production line on-site display: compact size IP65、 316 shell, suitable for dense equipment space, intuitive inspection reading, safe and efficient.
Over limit alarm/interlock: relay output, linked sound and light alarm, emergency stop/valve closing, 1-second response, anti overflow/empty tank/overpressure accidents.
Data upload/accumulation: Modbus communication, connected to the daily chemical MES system, formula/energy consumption statistics, fault tracing, meeting the quality tracing requirements of the daily chemical industry.
Addressing Industry Issues
The medium is viscous/cream (shampoo/cream), and the instrument is easy to stick and block: the ordinary instrument diaphragm is blocked, the signal drifts, the liquid level/pressure is inaccurate, the formula proportion is unbalanced, and the batch is scrapped.
High alkaline/weakly acidic media make instruments prone to corrosion
Ordinary metal instruments are corroded by surfactants/alkaline solutions, leading to 3-6 months of failure, frequent replacement, and high maintenance costs.
Too much foam (detergent/shower gel), distorted liquid level measurement
Ordinary liquid level meter is disturbed by foam, misjudges the liquid level, overflows/empties frequently, production interruption, and material waste.
The production line space is narrow, and traditional instrument installation is inconvenient
It is difficult to install large volume instruments, and there are many blind spots for cleaning, which affects the layout of the production line and does not meet hygiene standards.
Frequent batch switching, time-consuming cleaning/calibration
Ordinary instruments are complex to disassemble, slow to calibrate, long downtime for changing production lines, and low production efficiency.
Unstable emulsification/filling pressure, multiple product defects
Large pressure fluctuations, insufficient emulsification, uneven filling volume, low yield rate, and frequent customer complaints.
Direct Customer Benefits
Quality and yield return (core)
Accurate formula: ingredient ratio error reduced by ≥ 95%, batch consistency improved by ≥ 98%, layering/sedimentation/particle defects reduced by ≥ 90%, yield rate increased by 4% -6%.
Accurate filling: Filling errors reduced by ≥ 92%, customer complaints reduced by ≥ 90%, and brand reputation improved.
Production efficiency and capacity benefits
Anti adhesion/anti foam: the instrument failure rate is reduced by ≥ 90%, unplanned downtime is reduced by ≥ 95%, the effective production time is increased by ≥ 10 days per year, and the production capacity is increased by ≥ 3%.
Quick production change: The quick installation design reduces disassembly time by ≥ 80%, shortens downtime of the production line by ≥ 50%, produces ≥ 60 batches annually, and increases revenue by ≥ 1.5 million yuan.
Automatic control: manual intervention reduces by ≥ 75%, production efficiency increases by ≥ 45%.
Cost and energy-saving benefits (direct savings)
Raw material savings: Material waste is reduced by ≥ 10%, and the annual production of 50000 tons of laundry detergent factory saves ≥ 5000 tons of raw materials, resulting in cost savings of ≥ 2.5 million yuan.
Energy saving and consumption reduction: Reduce steam/electricity consumption by 3% -4%, with an annual energy-saving/steam cost of ≥ 800000 yuan.
Maintenance cost reduction: The lifespan of the instrument is 2-3 years, and the annual maintenance cost is reduced by ≥ 80%, reducing spare parts/labor expenses by ≥ 300000 yuan.
Compliance and management benefits
Sanitary compliance: 316L+PTFE with no dead corners design, passed the daily chemical hygiene audit, avoiding product contamination risks.
Data traceability: The formula/production data is precise and traceable, meeting the quality control requirements of the daily chemical industry and improving the level of management refinement.
