Weigh batching: the benefits of an automated system



Manual weigh batching, a function of lots of plants that batch-blend bulk products, involves the individual weighing of ingredients just before they're charged into a blender or other process vessel. An automated weigh batching system, providing a more-accurate and constant mixture, may very well be a viable alternative. Get much more facts about фасовка в мешки


In several plants that use manual methods, it really is popular practice to work with pre-weighed bags. You can find problems linked with this method, for example every bag might not include the specified amount of material or the worker might not empty the bag completely. Inaccuracies are compounded as more bags are used. In addition, if an operator is necessary to count bags to be able to achieve proper weight, there may be an elevated risk of human error.


There are two automated weigh batching procedures: gain-in-weight and loss-of-weight. Within the first arrangement, batch ingredients are usually conveyed in sequence into a hopper positioned above a process vessel, normally a blender or storage vessel. The hopper is set on load cells that transmit weight-gain information to a programmable logic controller (PLC) that begins the conveyor for each ingredient, then stops it when the preset weight for that ingredient is reached. Lastly, the controller automatically charges the batch for the process vessel.


When to specify a gain-in-weight versus a loss-of-weight system


One of the most suitable weigh batching method for the plant will depend on how and where bulk material is received and stored. If the material is delivered in rail cars or bulk trucks and stored in silos, which are impractical to mount on load cells required to get a loss-of-weight system, a gain-in-weight system is acceptable. Conversely, if material is received in bulk bags, a loss-of-weight system integrating bulk bag unloaders mounted on load cells could be the solution for you.


Integrating a weigh batching system into an existing process


An automated weigh batching system is generally integrated using the plant's bulk handling system, and typically incorporates pneumatic and/or mechanical conveyors. All upstream and downstream equipment, from receiving to processing or packaging, might be sealed to eradicate contamination of your product and plant atmosphere.


The entire operation could be automatically controlled. One option is always to use a scale interface card to link up with an current plant-wide PLC system; a second is usually to use a stand-alone PLC, and also a third will be to employ a sequential batch controller. The latter is actually a programmable device that will run each of the equipment connected with all the weigh batching system and retailer the product recipes. It might operate in stand-alone mode or be integrated to varying degrees using the plant PLC.


A weigh batching system ought to be engineered in line with the number, volume, flowability and place of supplies to become weighed, the respective strengths of loss-of-weight and gain-in-weight batching approaches, and also the new or current conveyors, control systems and processes with which it will likely be integrated. The availability of numerous weigh batching elements and numerous strategies in which they could be configured, allow the plant engineer to design a system that functions reliably, improves product high-quality and boosts output even though cutting cost.

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