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Kundeapplikationer 11. maj 2022

Modularity in Hazardous Areas

Filling, sealing and testing all types of aerosol cans is what Pamasol Willi Mäder AG in Pfäffikon, Switzerland does best. The safety of their machines is guaranteed by the WAGO Ex i Module, which offers several key advantages.

When Philipp Bruhin explains Pamasol’s business model, it does not sound particularly complicated. “We fill the container with a product, fit the valve on top and pump in the gas. Then we test it in a water bath, and finally we attach the spray nozzle and cap,” explains the head of the electrical department.

The Benefits in Detail:

  • The modular system design minimizes the footprint, since only as many modules as actually are needed are attached.

  • The coupler’s multiple connectivity options and various certifications allow flexible use of one system for different markets and their requirements.

  • The long-term availability of these products or compatible alternatives allows defective modules to be replaced even after twenty years or more.

When Philipp Bruhin explains Pamasol’s business model, it does not sound particularly complicated. “We fill the container with a product, fit the valve on top and pump in the gas. Then we test it in a water bath, and finally we attach the spray nozzle and cap,” explains the head of the electrical department.

Explained this way, it does not sound terribly difficult, but it takes decades experience to master the process perfectly. Since it was established in 1965, Willi Mäder AG has perfected this principle. “Nowadays, we build a custom solution for each container type and offer a complete process, from empty containers all the way to filled and tested containers, including the caps,” says Phillip Bruhin, describing his employer’s expertise and adding: “We fill all types of products very precisely and with a very high degree of consistency.”

The precise attachment and crimping of nozzles is a science in itself and requires decades of experience.

Process Challenges

It’s not quite as simple as it sounds at first. As an example, Philipp Bruhin describes the valve that has to be fitted atop the spray can and pressed on. If the machine does not press the nozzle on with enough force to form a leakproof seal, the propellant just vaporizes and leaks out. To prevent this, the operating pressure must stay within a specific range during crimping, as the sealing process is called in the aerosol industry.

Yet another challenge is the quality and tolerances of the spray cans. Some manufacturers find it hard to keep the height exactly the same during production, so additional engineering tricks are required is to detect and compensate for these differences when placing and crimping the nozzle. The trend towards thinner-walled containers to conserve materials also demands intelligent solutions to avoid producing large numbers of defective items.
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