Automated Bulk Chemical Handling
A Flow Stack is a valve stack that allows Mixmate software to automatically control the induction of bulk chemical into the carrier stream. It provides a fast, accurate, and closed way to move multiple bulk products without requiring the operator to manually open and close chemical valves.
Flow Stacks are one of the key building blocks of a Mixmate system, especially for operations handling multiple bulk products.
What Is a Flow Stack?
At its simplest, a Flow Stack is a vertical manifold made up of multiple controlled valves and a shared flowmeter.
A typical Flow Stack includes:
- A fresh-water rinse valve
- Three or four bulk chemical input valves
- A strainer
- A flowmeter
- A throttle valve
Each bulk chemical has its own input valve and hose connected to its respective bulk container. However, all of the inputs share the same flowmeter.
This shared flowmeter is an important part of the Flow Stack design. Instead of requiring a separate flowmeter for every chemical input, one flowmeter measures whichever product is currently being dispensed. This keeps the system more compact and helps reduce cost.
The name Flow Stack comes from the physical design—the valves and components are arranged in a vertical stack.
How Does a Flow Stack Work?
The Flow Stack is installed on the suction side of the carrier pump.
When Mixmate calls for a bulk chemical, the appropriate input valve opens and the suction created by the carrier pump pulls the product from its bulk container, through the Flow Stack, and into the carrier stream.
The flowmeter measures the amount of product being transferred while Mixmate controls the valves automatically.
As the target amount approaches, Mixmate begins slowly closing the Flow Stack’s throttle valve. This reduces the flow rate as the system gets closer to the target.
Once the target amount has been reached, Mixmate closes the chemical input valve.
This gradual reduction in flow helps the system hit the target more accurately rather than continuing to move a large volume of chemical while the system is trying to stop the flow.
Once that product is complete, Mixmate can move on to the next bulk chemical.
One Flowmeter, Multiple Products
One of the most important things to understand about a Flow Stack is that each product has its own input valve, but all of the products share one flowmeter.
This allows a single Flow Stack to handle multiple bulk chemicals without needing a separate meter for every product.
However, because all of the products use the same flowmeter, only one product is dispensed through a Flow Stack at a time.
The system automatically opens the valve for the product it needs, measures that product, closes the valve when the target is reached, and then moves on to the next product.
If an operation needs additional bulk products beyond the available inputs, another Flow Stack can be added.
How Many Products Can a Flow Stack Handle?
A typical Flow Stack has three or four bulk chemical inputs.
For larger systems, up to two Flow Stacks can be mounted on a control stand, allowing the system to handle more bulk products while still using the same basic Flow Stack concept. Multiple control stands can be added if more than two Flow Stacks are needed.
The Mixmate Fusion provides another option. A Flow Stack can be mounted directly to the Fusion inductor, creating a compact system that combines bulk chemical handling and hand-add capabilities in one package.
This modular approach makes it possible to configure the number of bulk inputs around the needs of the operation.
Flow Stack + Inductor
A Flow Stack and an inductor serve different purposes within a Mixmate system.
The Flow Stack handles bulk chemicals.
The inductor handles hand-add products and dry products.
When combined, they allow Mixmate to automate both sides of the chemical loading process.
Bulk products can be pulled automatically through the Flow Stack while the operator is prompted to add hand-add products through the inductor.
This is one of the reasons the Flow Stack is such an important part of many Mixmate systems.
A Closed System for Bulk Chemical Handling
Because the Flow Stack pulls bulk chemical directly from the product container through hoses and plumbing, the operator doesn’t have to manually transfer bulk chemical into an open tank or measuring container.
The chemical remains within the plumbing system as it moves from the bulk container into the carrier stream.
This closed-system approach reduces manual chemical handling while allowing Mixmate to control and record the amount of product being added.
For operations handling multiple bulk products, this can make a significant difference in both convenience and operator workload.
Flow Stack vs. Mixmate Flow
A Flow Stack can be used as part of a complete Mixmate system with an inductor, or it can be the primary chemical-handling component in a Mixmate Flow system.
A traditional Mixmate system might combine:
Inductor + Flow Stack + Carrier Control + Pumps + Mixmate App
Mixmate Flow takes the Flow Stack concept and uses it without an inductor for applications where automated bulk chemical handling is the primary requirement.
This gives operations another way to build a Mixmate system around how they actually mix chemical.
Why Use a Flow Stack?
For operations handling multiple bulk products, a Flow Stack provides several important advantages:
– Fully Automated
Mixmate controls the valves and flowmeter, allowing bulk products to be measured and dispensed without the operator manually operating chemical valves.
– Closed System
Bulk chemicals move directly from their containers through the Flow Stack and into the carrier stream, reducing manual handling.
– Fast
The carrier pump’s suction pulls chemical through the Flow Stack, allowing bulk products to be transferred quickly.
– Accurate
The shared flowmeter measures each product while Mixmate gradually reduces flow near the target to improve dispensing accuracy.
– Modular
Flow Stacks can be configured with multiple inputs and additional Flow Stacks can be added when more bulk products are needed.
Is a Flow Stack Right for Your Mixmate?
If you’re handling multiple bulk chemicals, a Flow Stack can be one of the most valuable additions to a Mixmate system.
The right configuration depends on how many bulk products you need to handle, how quickly you want to move them, and how the system will be laid out.
Whether you need a single three-input Flow Stack, multiple Flow Stacks on a control stand, or a Flow Stack mounted directly to a Mixmate Fusion, the system can be configured around your operation.
A Flow Stack isn’t just a group of valves. It’s the part of the Mixmate system that brings automated, measured, closed-system bulk chemical handling together.