Weight Batching and Blending System
An automated weight batching and blending system is computerized systems that proportion and blend materials together. The results in improved product quality, (as the mixture’s accuracy and consistency) are better compared to the manual addition of pre-weighed bags. Automated weight batching and blending systems connect load cells to valves, relay hardware, and process control software.
The system control how one or more feed equipment delivers different ingredients into a standard receiving vessel in pre-defined quantities.
In many industries, batch-blend bulk materials, weight batching is manual and hence time-consuming, as ingredients are measured separately before they are conveyed to a mixer or other processing machine. Irrespective of operations’ size, an automated weight batching and blending system is economically beneficial because it increases productivity, product quality and minimizes dirt and product loss.
Furthermore, it can be divided into two- loss-in weight automated system and gain-of weight automated system.
Gain-in weight Automated System
In a gain-in weight automated system, each set ingredients are transferred in order into a tool known as the hopper (usually on a process vessel), usually a grater or storage facility. The hopper placed in the load cells will communicate with a controller, that will create a conveyor for each material and ends it after the targeted weight for such ingredient is attained. The controller then automatically discharges the batch into the processor.
Loss-of-weight Automated System
On the other hand, in a loss-of-weight process, each ingredient contained in a preloaded hopper or bag unloader, is set on the load cells which send weight loss calculations to a processing controller. The controller begins and stops individual conveyor to weigh different ingredients.
Both systems can handle diverse free and non-free-flowing materials at the high rates needed for fast batching cycles and the steady feed rates required for accurate weighing. However, the destination of the bulk material determines which weight batching method is most suitable. For example, if the material is sent to bulk trucks or rail cars and is kept in silos, none of which meet the requirements of a gain-in weight system, a loss-of-weight application becomes preferable.
Conversely, if the material is received in bulk bags, a gain-in weight system offers a straight-forward solution.
An automated weight batching and blending system is often integrated with the plant’s bulk handling system and generally integrates with pneumatic and mechanical conveyors. The whole equipment, both upstream and downstream, can be sealed to prevent contamination of both product and plant environment from receiving to processing or packaging.
There are many factors to consider when deciding on the choice of conveying system, and the requirements of a chosen weight batching system are one of them. Also, an existing conveying system or a predetermined preference in bulk handling system can also influence the weight batching system’s choice.
Mechanical conveyors are appropriate for transporting both free and non-free-flowing materials over relatively short distances. They are suitable for both gain-in weight and loss-of-weight batching systems. A weight batching system should be constructed according to the volume, number, type, and location of materials to be weighed.
The respective strengths and weaknesses of gain-in weight and loss-of-weight batching methods, and the type of conveyor (new or existing), and the control systems are some other factors that should be considered. A weight batching and blending system guarantees a marked improvement in output that every industry desire.