INDUSTRIAL AUTOMATION, QUALITY MEASUREMENT AND LABORATORY SOLUTIONS

Manual Guided Batching System

Manual Guided Batching System
Project Overview

A chemical manufacturing company operates Banbury mixers for batch based compounding where accuracy, repeatability and traceability are critical to product quality. To address challenges associated with operator dependent manual weighing, a manual guided material charging system was implemented, providing guided weighing, controlled charging and batch data logging to ensure consistent and traceable production.

Project Details

Customer Challenges

  • Inconsistent manual weighing
  • No batch traceability
  • Operator dependency

Key Components

  • 50 kg Major Scale & 5 kg Minor Scale
  • Flex 2100 Weight Controller with SGM750 Indicator
  • FLEXER SCADA Software for Data logging & report generation
  • Curtain Sensor for feed confirmation

Solution Provided

  • Dual Precision Weighing Scales
  • Mixer PLC Integration
  • Recipe Management
  • Automated Reporting (Batch & Consumption Report)
  • Report Email Facility

Results Achieved

  • 100% Traceability
  • Faster Batch Execution
  • Enhanced Efficiency

Customer Benefits

  • High Accuracy & Batch Traceability
  • Improved Process Control
  • Reduced Downtime
Conclusion

The solution provides a scalable, reliable, and future-ready platform for batch processing operations, strengthening both production efficiency and quality assurance.


Description

In industries where accurate weighing dictates product quality, consistency is everything. Our Manual Guided Weighing System bridges the gap between manual labour and automated precision. It provides operators with step-by-step, foolproof guidance to ensure every batch is mixed exactly to recipe specifications, every single time.


By eliminating human error at the weighing station, this system brings automated-level accuracy and data logging to your facility—at a fraction of the cost of a fully automated batching system.


Key features are Intelligent Recipe Management, Step-by-Step Operator Prompting where intuitive interface guides operators through the sequence, clearly displaying which ingredient to add next and the target weight, Tolerance Lock which protects  batch by refusing to advance to the next ingredient until the current material is within the strictly defined tolerance window, Automated Report Generation.


Finds application in food, chemical and pharmaceutical industries.