Elmet has developed the new variant of the precision dosing system TOP 7000 Cast, designed for the specific requirements of casting, coating, and manual molding processes. The unit can operate with material supplied from 20- or 200-liter drums (5- or 55-gallon drums) and is characterized by high precision and process stability. In this way, Elmet is expanding its range of dosing systems with a standalone solution for applications outside classic LSR injection molding, for which the TOP 700, TOP 3100, TOP 5100, and flagship TOP 7000 Pro systems are designed. The new TOP 7000 Cast dosing system was presented to the public for the first time at the MD&M West trade fair in Anaheim, California (USA).
Constant volume flow and stable mixing ratio
The system developed specifically for casting applications is based on the high-performance TOP 7000 Pro model and combines a constant volume flow with a stable mixing ratio. This enables reproducible component quality, including when processing materials with highly variable viscosity and fillers. Up to five freely configurable ramp profiles are available to the user, enabling precise and reliable filling processes.
The option of freely selecting shutdown criteria, such as time, volume, filling pressure, or an external start/stop signal, facilitates adaptation of the system to different casting processes. Recipe management with calling up stored recipes within seconds via QR code is available as an option, which shortens setup times and reduces the risk of incorrect settings. Up to six additives can be mixed into the optimally mixed base material with an accuracy of +/- 0.01%.
Drum changes can be carried out from three sides and are fully automatic from the drum edge. For a pair of 200-liter drums, the changeover time is less than five minutes, enabling a quick production restart. Fully automatic venting ensures consistent process conditions with every change of material container.
Automated operation and cost efficiency
The intuitive software and self-learning control system, which automatically adapts to the conveying behavior of the material, help to reduce operating costs and increase process reliability. Conveying capacities of more than five liters per minute, depending on viscosity, make it possible to achieve 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, the system provides high cost efficiency over the entire service life, which often extends to twenty years or more.
The TOP 7000 Cast meets the requirements of EN ISO 13849-1 and is CE, RoHS, and UL compliant. The system is designed for all standard materials, flame-retardant materials, HVI materials, oil-resistant compounds, medical materials, and other special materials. The range of processable viscosities extends from 0.001 Pa to 3,000 Pa. For highly filled and abrasive materials, an optional wear-resistant version is available, designed for continuous operation without the need to shorten maintenance intervals.
Industrial applications requiring high precision
Typical applications for the TOP 7000 Cast system, where high precision, material homogeneity, and reproducible filling processes are critical, include direct filling (casting) of products for high- and medium-voltage applications, such as insulators (HVI) and composite hollow core insulators, as well as cable joints. Another group of applications is manual molding of medical products, including manifolds (distributors for liquids and gases), prosthetic liners, and medical cushions (orthopedic cushions), with or without a dispensing gun.
In fabric and paper release coating as well as in cable sheathing processes, where uniform and controlled material application is required, the TOP 7000 Cast utilizes the benefits of a continuous, stable volume flow, even with significant viscosity differences.
As a production solution for changing materials, small batch sizes, and high-quality requirements, the TOP 7000 Cast sets a clear standard for efficient, stable, and reproducible dosing processes in the casting environment.
