Case Studies: Batching Systems

View case studies and examples of industrial batching systems below. Batch large particles or very fine powders and then add to the remainder of a bulk processing system.

loss in weight hopper with electromagnetic vibrating feeder

Free standing Loss in Weight Hopper with Feeder includes vibrating feeder to meter material from the surge or supply hopper above the feeder.  The system is mounted on load cells with a scale controller and controls to operate the system. System uses an electromagnetic vibrating feeder with flow control to control the rate of discharge from the feeder. The surge or supply hopper can be sized for each application.

It is used for metering additive materials into a mixer or blending system. It is available in stainless steel or carbon steel construction. Control system is designed for independent control or integrated with an in-house process control system.

Loss in Weight Hopper with Electromagnetic Vibrating Feeder was last modified: March 25th, 2016 by Grant Rice
Chemical Blending and Batching System

Chemical Blending and Batching System
(click image for larger view)

This chemical blending and batching system was used for the toll blending of powder chemicals including calcium carbonate.  The final blended product was to be automatically packaged into bulk bags using a bulk bag filler.  It could also be packaged into smaller valve bags using a valve bag filler.

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Custom Blending & Batching System for Toll Blending of Powdered Chemicals was last modified: May 7th, 2013 by Grant Rice

Carbon Black Batching System for Seven (7) types of carbon blacks. They are simultaneously fed into individual weigh hoppers. Vibratory Feeders meter product into 16 cu. ft. Net Weigh Hoppers supplied with air-operated fast acting Roller Slide Gates.

Carbon Black Batching SystemUpon discharge, a Quiet Single Impactor Pneumatic Vibrator cleans the Weigh Hopper, before the gate closes. The batch is then transferred by Belt Conveyor to a 16 cu. ft. confirmation (check weigh) Hopper where the final weight is either accepted or rejected. Accepted batches go directly to the mixer. If a batch is out of tolerance it is rejected via a Pantleg Diverter into a portable storage container at floor level.

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Carbon Black Batching System was last modified: December 27th, 2016 by Grant Rice
Ingredient Batching System with Bulk Bag Unloading

Ingredient Batching System with Bulk Bag Unloading

This Minor Ingredient Batching System for Rubber Products consists of (13) 2-speed Electromagnetic Vibratory Feeders and (3) 2-speed Precision Volumetric Screw Feeders, manufactured in 304 Stainless Construction. The selection of feeder type was accomplished via testing at manufacturer’s processing and selection test center. Each product was tested and the type of feeder selected for accuracy and flowability.

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Ingredient Batching System for Rubber Products was last modified: November 9th, 2012 by Grant Rice
Carbon Black Batching System with Bulk Bag Unloading Station

Bulk bag unloading station uses intermediate frame to change carbon blacks often

Carbon black batching system with bulk bag unloading station for technical rubber. Customer required a clean method of batching out a desired amount of carbon black for their process.

A Gain-in-Weight Bulk Bag Unloading station with many unique features was designed. Because of the need to change the carbon blacks often, an intermediate frame complete with the unloader assembly was designed to allow the material to be changed while there was material maintained in the bulk bag. This is accomplished by simply closing a butterfly valve and lifting the frame out of a stationary feeding station. A second frame with a different material is then placed into the feeding station, the butterfly valve is opened, and the material change is complete. In addition to this unique feature, the station acts as a Gain-in-Weight Batching Station.

 The carbon black is metered out of the unloading station and into a plastic bin, which is indexed onto a scale. When initiated, the carbon black batching system will automatically dispense the proper amount of material (with an accuracy of +/- 0.1 lbs.) on a 75 lb. batch. The complete process is accomplished in a dust-free environment.

Carbon Black Batching System with Bulk Bag Unloading Station was last modified: November 9th, 2012 by Grant Rice
Bulk Bag Unloading Stations for Batching System

Bulk Bag Unloading Stations

This batching system was built for a manufacturer of engineered refractory products.  They required an automated system to batch and mix seven ingredients.  The customer had five existing exterior storage hoppers which where retrofitted with new feed screw conveyors. The new screw conveyors transported their product into a five-ingredient net weigh hopper. In addition to the materials fed into the net weigh hopper, there are two Loss-of-Weight Bulk Bag Unloading stations which are able to simultaneously feed the desired amount of material. Both the net weigh hopper and the Loss-of-Weight Unloading stations feed onto a collection conveyor for transport to the existing industrial mixer.

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Batching System for Engineered Refractory Products was last modified: November 9th, 2012 by Grant Rice

Specialty designed concrete batching system for concrete powdered products by weight, into a mixer. The components consist of a Bulk Bag Unloader on tank-type load cells, a 50 lb. Bag Dump Station with self-contained Dust Collector, a Twin Motor Vibratory, 2-Speed Feeder and an inclined corrugated side wall, cleated belt conveyor. All items were designed for dust tight operation.

The concrete batching system incorporates a custom software control package for “LOW” Loss of Weight batching. Batches up to 1500 lbs. are weighed with an accuracy of +/- 1 lb. A “refill pause” program enables removal of an empty bulk bag when a low level indication light is energized. Small 50 lb. bag additions or less, are hand-added at the Bag Dump Station. The system was factory tested and demonstrated to customer for their acceptance, prior to final shipment.

Concrete Batching System

Concrete Batching of Concrete Powdered Products by Weight was last modified: November 9th, 2012 by Grant Rice