Auto Batching Made Easier
Higher Efficiency, Faster Processing. Achieved.
Auto Batching Process
What was required:
A food processing business was under the hammer with increasing workloads and plant auditing requirements. The client was screaming out for a more accurate, faster and more comprehensive automated batching process.
The client needed weighing accuracy to the nearest single gram to increase processing times and improve batch reporting systems throughout the business. This will make their processes easier and swifter—from the factory floor to office admin.
What we did:
We chose the Rockwell 5380 processor due to its high speeds and large memory, making it ideal for small to midsize applications requiring high-speed I/O (input-output).
- The Rockwell 5380 provides enhanced diagnostics and controller functions including motion control, Device Level Ring/Linear Topologies and optimised troubleshooting and system performance.
- Its dual configurable ports support dual IP addresses handling full batching system processes and the option of reporting features if required.
The processing unit was then combined with the 12 x Rockwell 525 cat 3 Safestop Drive with inbuilt Ethernet communications.
- This provided faster integration and reduced wiring time. Key to its super efficiency and accuracy is the load cells for weighing systems.
Teaming up with Sensortronics, we were able to provide the perfect solution around weight accuracy for bins from 2 tonnes to 100 kg.
The product is distributed to one of nine bins and one operator begins the batching process.
The entire process is monitored every step of the way and at the first sign of any problem, the system defaults to hold mode, allowing the operator to check information alarms and quickly resolve issues.
The commonest problem is product bridging, where the product fails to be delivered at all throughout the batching process.
- Being carefully monitored, pneumatic air is blasted on dosing bins in anticipation of delivery, resulting in fewer stops/starts.
Once the batching process is complete, a printout and email are automatically sent out for reporting purposes.
How it helped:
The introduction of the new batching processor has resulted in a much more efficient system, which also allows customers to see their blend if requested, to confirm the exact product supplied.
Operating this batching process is now a cinch with order requests from the office or from local HMI touch screens loaded, scanned and confirmed for operation in lightning-fast times.
Is it time for your company to consider a new or upgraded batching process, particularly with increasing audit trials required by the Crown?
Call Steve on 021 919 041 to discuss your auto batching requirements and we’ll nut out the solution for you.
