Powdered Plaster Technology: Fully Automatic Dosing and Mixing Units
The most critical factor determining the quality, workability, and strength of powdered plaster products (plaster of Paris, satin plaster, machine-applied plaster, etc.) is the application of the formulation (recipe) with zero error in every production batch. Even a deviation of one-thousandth in the mixing ratios directly affects the final product’s setting time or surface adhesion.
Leveraging our expertise in plaster production plant infrastructure, IPS Makina designs and manufactures fully automated Dosing and Mixing Units that standardize the quality of your product recipes and completely eliminate errors caused by human judgment. Serving as the heart of your gypsum plant, these units—operating with advanced PLC and SCADA automation infrastructure—accelerate your production lines, prevent raw material waste, and maximize the profitability of your investment.
Our unit consists of two fundamental technological stages designed to ensure a continuous and precise powdered gypsum production cycle:
1. Dosing Systems (Precision Recipe Management)
In the production of powdered plaster, in addition to primary filler materials such as base plaster, calcite, or perlite, critical chemical additives (water-retaining agents, setting retarders, celluloses) are used, with their quantities expressed in grams. IPS Machinery dosing systems ensure that these raw materials are transferred from silos into the system in the exact quantities, at the correct speeds, and without any issues.
- Micro and Macro Dosing: While the main materials are stored in large silos, the precise additives that play a critical role in production are stored in specially designed stainless steel micro-dosing silos.
- Frequency-Controlled Flow: Thanks to inverter-controlled (speed-regulated) screw conveyors integrated at the base of the silos, the material flow is slowed as it approaches the target value, and transfer is performed with milligram precision using the drip (fine dosing) principle.
- Fluidization Technology: For raw materials that are difficult to fluidize and prone to bridging (clogging), continuous dosing is ensured through the use of pneumatic ramming and vibration systems.
2. High-Performance Plaster Mixer (Blender) Systems
This is the central unit where all metered components come together in a single housing to form the final plaster powder product. A high-performance mixer that meets industrial standards does more than simply blend the materials; it prevents clumping and ensures that the particles dissolve seamlessly into one another.
- Custom Design Based on Capacity: Single-shaft (plowshare) or double-shaft (paddle/ribbon) mixer systems are custom-designed for each project based on the composition of the plaster to be produced and your facility’s target tonnage.
- 100% Homogenization: Thanks to mixer blades positioned at specially engineered angles, no dead spots are left inside the housing. Depending on the complexity of the recipe, a fully homogeneous blend is typically achieved in very short times—usually between 1 and 3 minutes.
- Wear Resistance (Heavy Duty): Taking into account the highly abrasive nature of raw materials such as gypsum and calcite, Hardox (or equivalent) wear plates suitable for heavy industry are used on the interior of the mixer housing and the blades.
- Rapid Discharge and Easy Cleaning: When the mixing cycle is complete, the wide pneumatic valves (flaps) at the bottom of the housing open instantly using the blast-door principle, and the mixer discharges into the lower hopper within seconds. The wide access hatches on the housing allow for quick cleaning of the machine and shorter maintenance cycles.
How IPS Machine Automation Benefits Your Plaster Plant
- Full Integration: The dosing unit and mixer communicate with each other within fractions of a second, eliminating wait times and ensuring a continuous production cycle.
- Full Traceability: Full production control through smart SCADA systems that report how many metric tons of plaster were mixed from which recipe at what time.
- Dust-Free Work Environment: Zero product loss and an environmentally friendly, clean factory floor thanks to jet-pulse dust collection systems connected to all transfer and mixing points.
