Batching is a complex manufacturing process in which as many as several dozens of diverse ingredients must be mixed in exact proportions.
Often, batching is a multi-station process where each stage makes the product in question more complete.
Here are a few use cases for batching:
- Baked good production
- Sports shoe and athletic wear production
- Producing bottled/canned beverages
- Paint production
- Ink production
- Adhesive and glue production
- Flat-pack furniture making
- Jet engine production
- Computer chips
- Electrical goods (calculators, scales, & so on)
…and more. Let’s delve into why scales are such a key piece of equipment for this production process.
Why Batch Weighing Scales Are So Important for This Production Process
Many of the elements of batch production are handled by weighing materials, as are final QA processes are achieved by weighing operations.
Often, the weighing equipment will have other sensors to gather measurements beyond weight. The design of the scale itself makes this possible.
Sometimes this process involves joining weight sensors to a bin, bucket, or the like and then delivering the signal to a digital indicator or similar device achieve these measurements.
This eliminates the need to manually weigh each ingredient before discharging and processing it, a time consuming and occasionally inexact procedure in which many plants still engage.
Automation is one of the best ways to ensure consistency and efficiency in your production process. However, you need the right hardware and software to make it work for you.
The Ideal Design Elements for An Automated Batch Production Scale
Ideally, an automated batch weighing scale will integrate connections, valves, process control software, a load cell, and relay hardware into a single system that is then incorporated into a scheme designed to deliver the varied ingredients to a container in which those ingredients will be blended.
Measuring Temperature: A Common Element of Batch Production
Temperature is a key element for many chemical reactions (including those in baking, for example), which is why the best scales for this purpose are able to measure and control temperature conditions in the container.
Industrial Digital Filling Scales: How to Create A Mix of Multiple Ingredients
Industrial digital filling scales can be used for basic batching operations when many different ingredients will be used.
For each individual ingredient, a separate set point value is assigned. The set point output stops after the first level is completed and the second begins, and so on. Scales with this function include floor scales, drum scales and platform scales.
Arlyn Scales offers a number of accessories on scales that help you build the data infrastructure you need to collect, store and transfer your measurements, and the hardware you need to use these measurements in your production process.
Storing and Reproducing Formulas for Batch Production with Digital Industrial Filling Scales
Digital industrial filling scales with batching function often have memory capabilities, so these formulas can be saved and used again. Sometimes as many as a hundred formulas can be stored in a single scale, making it a versatile tool that can accommodate an evolving production process.
These types of scales usually come standard with an RS-232 connection, but since that requires close proximity to a computer, they are more frequently being outfitted with…
- USB (Universal Serial Bus)
- Ethernet ports
- The USB port allows a thumb drive to be connected to the scale as well.
…and more available options.
All batch, formula and weight data are downloaded onto the drive, and then the thumb drive can be delivered to any computer system and exported into spreadsheets or data tables. With an Ethernet connection, the digital filling scale is hooked up to the facility’s network. Information can be recorded remotely and, using software, the scales can be operated from a distance.
Building A Network of Scales with Shared Data: Perfect for A Growing Production Entity
Several of our electronic scales can be networked together to work in unison and share data. This technology improves quality through accuracy and consistency.
Digital indicators for industrial scales can also perform batching operations. These programmable indicators are often high resolution and easy to set up and use. A model with a numeric keypad is ideal and can be used to enter and track set points for batching, as well as tare information, unit conversion, label layouts and descriptions of parts (for parts counting).
There are two different types of batch weighing modes: normal and loss in weight batching. Loss in weight batching is a method in which the container is weighed when the batch is started.
Dispensing of the ingredient is stopped when the target weight is reached. Some digital indicators have high sampling speeds of up to 70 times per second. The same USB and Ethernet technology is available for digital indicators. If the digital indicator will be used in a harsher environment, consider special casing that will be shock absorbent and waterproof.
Learn More About Platform Scales for Your Manufacturing Facility
Arlyn Scales is a leading manufacturer of industrial scales for facilities of all kinds. We designed cutting edge load cells and scale technology to creates scales that are more accurate, more reliable, and longer lasting. We’ve outfitted an incredible number of manufacturing facilities with scales that have improved their functions and operations. We can offer guidance on prices, options, and necessary upgrades. Contact us online, where you can browse through our batch weighing scales, not to mention the sizes, capacities and upgrades we offer.