Common Fluid Dispensing Challenges and Their Solutions

Inconsistent fluid dispensing volumes are a common issue for manufacturers, often leading to product defects, rework, or wasted materials. Jeff Schnapp, Regional Sales Manager at Designetics, points out that ensuring the flow of fluid matches the production speed is key. “We focus on making sure fluid delivery is married to the speed of the process by creating flow 'curves' based on RPM and the customer’s environment." This synchronization can prevent over-application or under-application of fluids, which are frequent causes of inefficiency.

Solutions:

• Use advanced sensor technology to monitor flow rates.
• Ensure regular maintenance of systems.
• Design solutions that match fluid flow to the production speed.

High-viscosity fluids, such as adhesives and sealants, present unique challenges, often clogging, slowing down, or applying unevenly. Jeff notes that Designetics often steps in when other systems are overengineered for low-viscosity fluids but underperform with thicker materials. "Our peristaltic technology ensures the fluid only touches the inside of the tubing, simplifying maintenance and minimizing waste."

Solutions:

• Use peristaltic pumps for consistent flow.
• Apply systems designed specifically for thick fluids.
• Incorporate flow rate adjustments to ensure smooth dispensing without excess pressure buildup, reducing the risk of clogs.

Ensuring that the materials in your dispensing system are compatible with the fluids you are using is critical for long-term system performance. Jeff explains that Designetics tests all fluids for compatibility with their tubing, applicators, and system components in their lab. "Our materials are 100% compatible with 95% of all fluids, ensuring chemical reactions or corrosion don’t compromise the process or product quality."

Solutions:

• Test fluid compatibility with system materials before scaling.
• Regularly inspect and maintain systems to prevent long-term damage.
• Use materials specifically designed for fluid compatibility.

In high-speed production environments, maintaining precise fluid dispensing is crucial. Jeff highlights that Designetics designs systems to adjust instantly to changes in speed, allowing their pumps to go from 1 RPM to 300 RPM instantaneously. "This precise control prevents unnecessary waste and ensures that the applicator remains active as much as possible."

Solutions:

• Implement high-speed dispensing systems with flow control.
• Synchronize dispensing systems with production lines.
• Automate real-time adjustments to maintain precision.

While temperature-sensitive fluids can affect viscosity and application behavior, Designetics doesn’t directly offer heating or cooling solutions. However, Jeff explains that understanding how seasonal changes impact fluid performance is essential for customers. “We advise clients on adjusting their systems for summer versus winter conditions.”

Solutions:

• Monitor ambient temperature and adjust system parameters.
• Store temperature-sensitive fluids in controlled environments.
• Adjust fluid storage or application to manage seasonal changes.

Overcoming common fluid dispensing challenges is essential for maintaining high-quality production and minimizing waste. By addressing issues like inconsistent volumes, material compatibility, and viscosity challenges, manufacturers can improve both their efficiency and product quality.

At Designetics, we specialize in creating fluid dispensing systems that address these challenges head-on. From customized solutions for high-viscosity fluids to precision control in high-speed environments, our team works closely with clients to develop systems tailored to their specific needs. Our unmatched service includes in-lab or on-site testing and ongoing support throughout the installation process. As Jeff Schnapp, Regional Sales Manager at Designetics, mentions, "Customers are often surprised by how much we can help. Many say, ‘I had no idea these things were even possible.’" With a full team of engineers dedicated to ensuring optimal performance, Designetics delivers reliable, innovative solutions for your fluid dispensing challenges.