The manual application of viscous media using brushes, spatulas, or similar tools is still common practice in many production environments. For simple applications, small batch sizes, or frequently changing individual processes, this approach may suffice. However, as soon as defined application quantities, stable cycle times, and documentable quality are required, manual media application quickly reaches its limits.
Especially with oils, greases, adhesives, sealants, release agents, or pastes, the result depends heavily on the operator's experience, care, and even their performance on the day. Application quantity, distribution, layer thickness, and position can vary from component to component. The consequences are rework, scrap, increased material consumption, or altered functional properties of the component.
Industrial Dosing systems The medium is delivered to the component in a controlled manner via a defined material supply and suitable valve technology. Depending on the application, the application can be manual, semi-automatic, or fully automated. The interplay between the medium, the application quantity, the application pattern, and the component geometry is crucial.
Less waste through controlled application: Insufficient media volume can impair the component's function. Excessive volume often leads to contamination, rework, or unwanted media leakage. Such fluctuations can be reduced through precisely calibrated dosing parameters. Dosing time, pressure, valve position, and movement sequence are adapted to the medium, component, and cycle time requirements. For more complex component geometries, higher production volumes, or automated manufacturing processes, the media application can be implemented in a customized solution. Special machinery to get integrated.
More efficient media consumption: Many technical media are expensive or complex to process, such as specialty greases, adhesives, sealants, or functional coatings. By using defined dispensing quantities, only the amount of medium required for function, wetting, or bonding is applied. This reduces unnecessary media application, cleaning effort, and material costs.
Reproducible commissioned image: With manual application, uniformity, position, and layer thickness are only repeatable to a limited extent. Dosing systems enable dot, line, bead, spray, or area applications with adjustable media volume and defined application geometry. This allows the result to be better adapted to sealing surfaces, lubrication points, bonding surfaces, or hard-to-reach component areas.
More stable cycle and process times: Manual application steps are subject to natural variations. Dosed or automated processes operate with defined process parameters and repeatable motion sequences. This can shorten cycle times, stabilize cycle times, and increase production capacity. Especially in serial processes or recurring assembly tasks, a controlled application of media directly impacts process reliability.
Process monitoring and documentation: Modern dosing systems can be combined with sensors, control technology, and process monitoring. Depending on the application, pressure, temperature, dosing time, valve status, or material flow can be recorded and analyzed. This allows deviations to be detected earlier, quality-relevant process data to be documented, and maintenance or optimization potential to be derived more effectively.
When is it worth switching?
Switching from brush application to controlled application is particularly beneficial when dealing with recurring order processes, high production volumes, expensive media, or increasing quality requirements. Controlled application can also offer significant advantages for component geometries that are difficult to access, high rework costs, or requirements for process monitoring and documentation.
Controlled application does not necessarily require a fully automated system. Often, simply switching from a brush to a suitable dispensing or application system is enough to improve application quantity, distribution, and repeatability. Crucially, the material supply, dispensing rate, and application technology must be compatible with the medium and the component geometry. This article explains which factors are decisive for the automation of dispensing processes. Automating dosing processes.
Targeted optimization of media assignments: Whether brush application, manual application, semi-automatic device or fully automated dosing system: Every process should be measured by how reliably, economically and repeatably the desired application result is achieved.
WALTHER Systemtechnik supports you in evaluating existing application processes, identifying optimization potential, and designing suitable solutions for conveying, dosing, and applying viscous media. Upon request, we will test your application in the Dosage test using the original medium and original component to ensure the appropriate dosing procedure is used in a practical manner.