Language
First of all, its measurement accuracy is one of the key indicators. High-precision metering batching plant systems often achieve extremely high metering accuracy, such as ± 0. 01% or even higher. This means that in the batching process, various raw materials can be accurately blended according to the preset proportion, which greatly improves the stability of product quality. Whether it is the precise addition of various additives in the food processing industry or the precise ratio of different chemical components in chemical production, high-precision measurement can ensure the consistency of product performance.
Secondly, the batching speed is also an important parameter to measure the system. Advanced high-precision metering and batching equipment system has fast and efficient batching capabilities. It can complete a large number of batching tasks in a short time, which greatly improves production efficiency. Take some large-scale manufacturing industries as an example, it may be possible to complete dozens or even hundreds of precise ingredients per minute, meeting the needs of large-scale production. Moreover, the stability of its batching speed is also very important, and there will be no obvious speed fluctuation due to long-term working or continuous batching.
Ⅰ. High-Precision Batching System Technical Definition And Core Functions
The high-precision batching system is a comprehensive system that integrates automatic precise control, high-precision dynamic weighing, data transmission and analysis. It realizes automatic control of the production process through accurate measurement, proportioning and transportation of raw materials. Its core features include:
Multi-material synchronous control
Using PLC as the core, it can control multiple scales at the same time to achieve accurate output of various materials.
Supports simultaneous batching of 3-18 kinds of raw materials, including powder, granule, liquid and ultrafine powder.
Intelligent batching time management
By optimizing the batching cycle, the batching time is shortened and the yield is increased.
It has the function of automatically changing warehouses without materials to ensure continuity of production.
Data logging and reporting functions
Collect production data in real time (such as raw material dosage, proportion, production time), and support historical data query and export.
Provide powerful report function to facilitate quality traceability and production management.
Human-Computer Interaction and Remote Control
With manual/automatic, remote/local conversion functions, it is simple to operate and easy to maintain.
Supports remote monitoring and parameter adjustment to improve system flexibility.
Ⅱ.High-Precision Automatic Batching System Industrial Application Scenarios
1. Pharmaceutical Industry (the most demanding)
API synthesis
Accurately control the trace addition of catalysts and high-risk raw materials with an error ≤ 0. 1% to avoid out-of-control side reactions.
Solid formulation manufacturing
Mix active pharmaceutical ingredients and excipients to ensure content uniformity (RSD < 2%) and meet FDA standards.
Biopharmaceutical
The precise preparation of cell culture medium components, with an error of ± 0. 5%, ensures the stability of cell culture.
Core Value: Avoid batch recalls and pass FDA/GMP audits.
2. Food Industry (large-scale application)
High-end bakery and dairy products
Trace addition of yeast, emulsifier, vitamins, etc. (± 0. 2%) affects the fermentation speed and taste consistency.
Healthy Food and Meal Replacement
Control the proportion of protein, dietary fiber and sugar substitutes, and accurately match nutrition labels.
Condiments and Flavors
The ppm level of spices is added, and the error ± 0.01 g/kg determines the flavor level.
Typical case: A milk powder factory reduced the nutrient deviation from 3% to 0.5% through a high-precision system, reducing the annual complaint rate by 90%.
3. New Energy Materials (technological frontier)
Lithium battery positive and negative electrode materials
The ratio accuracy of nano-scale lithium cobalt oxide and ternary material (NCM) is ± 0. 3%, which is directly related to the energy density of the battery.
Photovoltaic silver paste
The ratio control of silver powder to glass powder (accuracy 0.1%) affects the gate line conductivity and component efficiency.
Hydrogen fuel cell catalyst
Precise control of platinum carbon loading (± 0. 05 mg/cm ²) reduces the amount of precious metals by 30%.
Technical challenge: Nano-powder is easy to agglomerate and requires pneumatic conveying + special design of weight loss feeder.
4. Fine Chemicals (High Value-added Scenarios)
Electronic chemicals
The ratio of photoresist resin to photosensitizer (error ≤ 0. 1%) determines the chip line width accuracy.
High-end coatings
The ratio of titanium dioxide and color paste is controlled (± 0. 2%) to ensure that the color difference ΔE between batches is < 0.5.
Catalyst Preparation
The control of the loading amount of molecular sieve support and active metal affects the catalytic efficiency.
Pain point solution: Avoid excessive addition of precious metals, and save more than one million yuan in raw material costs per year for a single line.
Ⅲ. Advantages Of High-Precision Batching Control System
The high-precision batching system has shown significant advantages in many industrial fields by integrating advanced technology and automation control. Its core advantages are as follows:
1. Extraordinary precision and accuracy
Dynamic and static high precision: static accuracy ≤ 0. 1% FS, dynamic accuracy ≤ 0. 2% FS, ensuring that micro or large batch ingredients can be accurately controlled.
Excellent error control: By optimizing sensor installation, scale bucket design and transmission system, residues and interference are greatly reduced. For example, the dynamic error at a full scale of 50kg is only ± 100 g.
2. Multi-material synchronous control capability
Supports simultaneous batching of 3-18 kinds of raw materials: covering powder, granule, liquid and ultra-fine powder, significantly improving production efficiency.
Automatic warehouse change function without material in the warehouse: Ensure the continuity of production and avoid downtime caused by raw material shortage.
3. High level of intelligence and automation
PLC core control: realize the collaborative work of multiple scales, optimize the batching cycle and shorten the production time.
Manual/automatic, remote/on-site conversion: flexible operation, easy maintenance, supporting remote monitoring and parameter adjustment.
4. Comprehensive data recording and traceability functions
Real-time data collection: record key data such as raw material dosage, proportion and production time.
Historical data query and export: Provides powerful report functions to facilitate quality traceability and production management optimization.
5. Significantly improve product quality and stability
Accurately control the proportion of raw materials: for example, in the food industry, the taste consistency of each batch of products is ensured, and in the pharmaceutical industry, the ingredients are fine controlled.
Improved quality stability: The quality stability of drugs is improved by more than 80%, meeting strict production standards.
6. Reduce security risks and labor costs
Automatic batching in closed environment: In industries such as hazardous chemicals, reduce manual contact with hazardous raw materials and improve safety.
Reduce manual intervention: Automated control reduces human error while saving labor costs.
7. Adapt to multi-formula and flexible production needs
Flexible adjustment of formula: adapt to the production needs of different products, such as accurately controlling the proportion of iron ore and coke in the metallurgical industry.
Modular design: Supports differentiated site planning and customer requirements, and is easy to expand and maintain.
8. Advantages of environmental protection and airtight design
Directional dust collection and closed weighing: reduce dust leakage, protect the environment and improve product quality.
Meet the needs of sustainable development: Promote green manufacturing by optimizing energy consumption management.
9. High reliability and fault tolerance
Dual hybrid system design: When one equipment fails, the other can operate independently to ensure that production is not affected.
Regular calibration and maintenance: By regularly calibrating the weighing equipment, the normal operation of sensors and actuators is ensured, and the long-term stability of the system is improved.
10. High productivity and economic benefits
Annual production capacity has been significantly improved: for example, the annual production capacity of concrete in the building materials industry can reach 1,000-5,000 tons.
High return on investment: Although the initial equipment cost is high, in the long run, significant economic benefits can be achieved by improving efficiency, reducing waste and labor costs.
Ⅳ. System architecture and optimization direction
4.1. System Architecture
Modular design: Supports differentiated site planning and customer requirements, and is easy to expand and maintain.
Dual hybrid system: When one fails, the other can operate independently, improving system reliability.
Optimization direction
Adaptability of formula design: Adjust the formula according to the characteristics of raw materials to avoid the accuracy problem of small amounts of raw materials.
Equipment maintenance and calibration: Periodically calibrate the weighing equipment to ensure the normal operation of sensors and actuators.
On-site management: Closed weighing and directional dust collection are adopted to reduce dust leakage, protect the environment and improve product quality.
4.2. Core Components
Weighing System:
High-precision sensors: core components, such as strain gauge sensors and electromagnetic force compensation sensors (the highest accuracy and high cost). High resolution, low drift, and good anti-interference ability are required.
Weighing platform/hopper: used to carry materials for weighing. The design needs to consider stiffness, dustproof, easy cleaning and no residue.
Weighing terminal/instrument: Receive sensor signals, perform high-precision analog-to-digital conversion, filtering, calculation, and provide human-computer interaction interface. Supports multiple communication protocols.
Feeding/Delivery System:
Type: Select according to material characteristics (fluidity, density, particle size, viscosity, etc.):
Micro/small range: peristaltic pump, plunger pump, micro screw, micro vibrating feeder, loss-in-weight feeder (highest accuracy).
Powder/granule: screw feeder (single/twin screw), vibrating feeder, pneumatic conveying, rotary valve, gravity artesian flow.
Liquids: metering pumps (gear pumps, plunger pumps, diaphragm pumps), mass flowmeters, control valves + flowmeters.
Critical: The controllability, uniformity, response speed and minimum controllable flow rate of the feeding directly affect the accuracy.
Control system:
PLC/Industrial PC: The brain of the system, which executes recipe logic, coordinates the actions of various components (start/stop feeders, valves, etc.), processes weighing data, and implements control algorithms.
High precision control algorithms: core software technologies. Weight loss control or weight gain control are commonly used. Intelligent algorithms (such as predictive control, adaptive PID) are needed to overcome factors such as material flow inertia, bridging, and adhesion to achieve precise “advance” control and avoid overshoot.
HMI: Operator interface for recipe selection, parameter setting, process monitoring, alarm display, data query.
Actuator: valve (pneumatic/electric ball valve, butterfly valve, pinch valve), drive (frequency converter, servo drive control feeder speed).
Mixing Systems: For applications requiring instant mixing, high-precision batching systems are often closely integrated with mixers (ribbon mixers, V-mixers, double cone mixers, high-speed shear mixers, etc.).
Auxiliary Systems:
Dust removal system: deals with dust generated by powder materials.
Cleaning System: Meets frequent recipe changes or high hygiene requirements.
Screening/iron removal: Ensure the purity of the material.
Safety protection: emergency stop, interlock, safety door, etc.
