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Why is the Topstar gravimetric blender the best choice for metering and mixing?

2026/02/02 By le zhan

gravimetric blender 2

When you rely on expensive masterbatches or variable additives, even minor deviations in proportion can lead to economic losses and affect product performance. The Topstar gravimetric blender is designed to address these pain points effectively. As auxiliary equipment specifically designed for injection molding, the Topstar plastic gravimetric blender accurately meters and mixes two to six raw materials, including virgin resins, recycled materials, masterbatches, and additives, at high speed, with processing capacities ranging from 20 kg/hour to 1000 kg/hour. Thanks to high-precision weight sensors and advanced control logic, batch mixing ratio errors can be precisely controlled between ±0.3% and ±0.5%, meeting the most stringent production specifications. Combining precision, processing capacity, and integration, it is the most practical and economical choice for manufacturers who prioritize consistent plastic part quality and reduced material costs, and is specifically designed for injection molding applications requiring precise control of material ratios.

Gravimetric Blender Metering Accuracy, Multi-Component Mixing, and Throughput Range

The core of any gravimetric blender lies in its ability to weigh accurately and control material flow. Topstar designed the gravimetric blender to meet the practical needs of injection molding: precisely dispensing masterbatches, controlling the proportion of recycled materials, and accurately adding trace additives such as flame retardants, stabilizers, and pigments. It supports 2 to 6 dosing channels, enabling standard production formulas such as virgin material, recycled material, masterbatch, lubricant, and stabilizer. You can configure each channel for continuous or intermittent batch addition, depending on your process requirements.

The Topstar gravimetric blender offers:

Capacity Flexibility: 20–1000 kg/hour, meeting the needs of various applications from small R&D workstations to high-volume production units. This range reduces the need for multiple blenders in the same workshop.

Precise Weighing: High-precision weighing sensors and short-cycle control technology enable batch mixing ratio errors to be controlled within ±0.3%–0.5%, depending on the compound type and set values. Repeatability: Consistent, periodic dosing reduces part-to-part variations, lowers scrap rates, and ensures downstream process setpoints (flow rate, temperature, cooling) match predictable part performance.

Gravimetric Blenders

Maintaining weighing accuracy of ±0.3%–0.5%

Topstar utilizes high-precision weighing sensors and robust signal conditioning technology to measure raw material weight in real time. As a result, the mixer maintains target ratios within ±0.3%–0.5%, a range that meets the demands for precise color control and critical additive metering in demanding injection molding applications. More importantly, Topstar optimizes its control logic for both small-batch accuracy and high-volume throughput. At low production rates (20–100 kg/hr), the system prioritizes acceptable metering resolution; at high production rates (hundreds to 1000 kg/hr), it prioritizes stable dynamic response.

Furthermore, the user interface provides precise diagnostics and trend data, allowing operators and engineers to verify performance at a glance. If any feeder’s flow characteristics deviate from expectations, the system flags the issue and logs the event. This diagnostic transparency reduces downtime and enables maintenance teams to identify the root cause quickly.

Maintaining weighing accuracy of ±0.3%–0.5%

Seamless Integration with Auxiliary Equipment

Modern injection molding demands that gravimetric blenders not only be highly accurate but also easily integrated into production cells and compatible with injection molding machine control systems and Central Manufacturing Execution Systems (MES). Topstar has designed this gravimetric blender as an auxiliary device that plugs directly into the production process.

Standardized Interfaces: Modbus, OPC UA, and discrete I/O enable the gravimetric blender to communicate with injection molding machines, material handling systems, and plant control systems. This supports recipe-driven production, where material ratios are part of the machine’s mold program.

Compact, Modular Layout: The Topstar plastic gravimetric blender features modular feeding stations that operators mount above a standard mixing hopper and can quickly remove or reconfigure to accommodate color or material changes. This reduces downtime during product changeovers.

Automatic Feeding Compatibility: The gravimetric blender is compatible with automatic loaders. It can receive bulk materials (large bags) or serve as an inline feeder for masterbatches and additives.

Additionally, the gravimetric blender’s touchscreen interface displays target setpoints, real-time weight, deviation alarms, and historical batch logs. Operators can lock recipes and restrict parameter changes through user-level permissions. When the injection molding machine loads a mold program, the blender receives its material recipe and automatically sets the metering ratio and feeding status. This reduces human error during the material setup process.

Lower Material Costs, Improved Quality, and Enhanced Recycling

Precise gravimetric blending delivers direct benefits in three operational areas: lower material costs, improved product quality, and better integration of recycling.

Lower Material Costs:

Precise Masterbatch Dosing: Masterbatches and high-value additives can cost several dollars per kilogram. Controlling dosing to within ±0.3% avoids over-addition, which often leads to unnecessary cost increases in the production of each part.

Optimized Regrind Utilization: By precisely metering regrind into the mixture, manufacturers can increase the regrind content while maintaining performance. Topstar’s gravimetric blenders enable you to confidently improve the regrind proportion incrementally and monitor part quality at each step.

Quality Improvement:

Uniform Color and Mechanical Properties: Precise blending reduces flashing, streaking, and variations in mechanical properties caused by inconsistent additive amounts. This helps improve first-pass yield and reduce customer returns.

Repeatable Mold Changes: Recipe-based operation eliminates operator variability during setup, ensuring consistent parts after each mold change. This is especially important in multi-shift and multi-product blending environments.

Promoting the Circular Economy:

Controlled Regrind Addition: Topstar gravimetric blenders enable precise, testable regrind addition. Through controlled dosing and accompanying process monitoring, engineers can evaluate the optimal amount of regrind to add without compromising part performance.

Designed for applications requiring precise control of material ratios.

The Topstar gravimetric blender combines laboratory-grade weighing accuracy with industrial-grade durability: it can precisely meter 2 to 6 raw materials with a throughput range of 20 to 1000 kg/hour, and the weighing error is controlled within approximately ±0.3% to 0.5%. In practical applications, this translates to predictable colors, reliable mechanical performance, and less time spent troubleshooting material quality issues. Whether used in conjunction with automatic feeders or integrated into centralized auxiliary equipment, the Topstar gravimetric blender delivers repeatable results—exactly what injection molding processes require.

 

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