bulk bag unloading into automated batching system

Turnkey Automated Batching System Helps Company Reach Sustainability Goals

Biosphere selected a turnkey automated batching system engineered and manufactured by Ingredient Masters Inc. of Cincinnati, Ohio on the basis of speed, repeatability, lead time for completion and cost.

The first of the five modules is a super sack bulk handling system comprised of six 54 cu. ft. dispensing hoppers arranged in a single row. Each is equipped with pneumatic slide gate valves with dual dribble positions to optimize cycle times and discharge accuracy. Air-activated vibration at each hopper is controlled by a PLC to ensure consistent product flow. A robotic scale cart, also governed by the PLC, moves under the dispensing hoppers and receives the precise amount of each ingredient specified in the recipe. The scale cart automatically docks with a transfer hopper to transport the ingredients. There are computer- controlled dust collection points at each of the five hopper discharge sites; dust collection can also be activated manually during hopper refilling.

The second module, a vacuum transfer system, is controlled by the central computer system. It automatically requests delivery of the next sequence of material whenever a premix hopper is empty. It has a primary premix hopper mounted over the mixer that discharges through the mixer port, and a secondary premix hopper that discharges into the primary. A vacuum receiver mounted above the secondary hopper transports ingredients sequentially from the scale cart transfer hopper into the secondary premix hopper. Module 3 is a fiber handling system with a mechanically agitated hopper mounted on load cells. It functions as a “loss in weight” scale hopper and can also be filled from an existing fiber shredder discharge conveyor.

System control is provided by an Allen Bradley Compact Logix PLC running RSLogic 5000 for the PLC logic and RS view for operator graphics. A Dell Pentium computer runs Windows XP and RSLix provides PC to PC communication. A Microsoft Access database stores recipe and ingredient information and records batch data. Read more about this case study.

Powdered Beverage Producer Installs An Automated Weighing and Batching System to Increase Production and Improve Efficiency

Ingredient Master installed the custom-designed automated gain-in-weight weighing and batching system in the batching room of Insight Beverages, Inc. in early 2010. The system consists of 20 removeable 28-cubic-foot ingredient dispensers, 20 screw feeders with helix screws, one powered infeed roller conveyor, five scaling rollers, one powered outfeed conveyor with a check weigh station, and one PLC controller that controls the entire system’s operation. Read more about this case study.

The Hempel Group chose Ingredient Masters automated batching technology for its manufacturing facility in Hong Kong

Start-up was completed in March 2010. An Ingredient Masters Automated Batching System was also chosen for the company’s manufacturing plant in Buk, Poland which opened April 27, 2010. The Poland project was CE certified and ATEX certified; the system for Hong Kong was built to the same specifications. The Hempel Group is a leading global supplier of coatings for marine, container, protective and decorative applications.

The installation at Hempel Poland is CE certified and ATEX certified. It is a two-floor configuration, with discharge of individual ingredients from 1000 kg bulk bags and 25 kg bags, from the upper floor.

Start-up and training is now complete at Hempel Poland, where an Ingredient Masters 24-station dry ingredient batching system will enable the company to manufacture 40 million liters of coatings per year.

The tanks for the Hempel project were manufactured from a permanent, semi-conductive polyolefin compound that provides excellent resistivity to static charges, and excellent flow and impact properties.