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A bulk bag batching station can improve batching efficiency and
reduce ingredient and handling costs.
Batch size, pounds, min. and max.
- Time to dispense batch, minutes, min. and max.
- Time to dispense batch
- Tamped and untamped ingredient bulk density
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A bulk bag batching system is comprised of a bulk bag discharger
whose outlet is directly coupled to a feed control device such as
a screw feeder or flexible conveyor. The feed device is typically
supported by the bulk bag discharger support structure. A microprocessor
based batch weigh controller is also included in any system.
There are 3 ways to batch directly from a bulk bag: two loss-in-weight
methods and an add weigh method. |
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The first loss-in-weight method, which is the most efficient, is
where the entire bulk bag discharging station is weighed and the batch
controlled by measuring the weight loss as ingredient is fed into
a conveying system or directly into a receptacle (mixer, blender,
tank, etc.). |
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The second, more costly, loss-in-weight method requires a separate
loss-in-weight feeder complete with refill hopper and refill valve,
to be suspended below the discharger outlet. |
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The add weigh method involves feeding product from the bulk bag
into a weighed receptacle.
Choosing the correct system application for your process requires
examination of three main criteria: accuracy, cost and space availability.
A loss-in-weight system where the entire station is weighed is suitable
for dispensing batches over 100lbs. in weight with an accuracy of
± 1-2 lbs. and is the least costly of the three configurations.
For batch sizes less than 100lbs. , or for accuracies greater than
1-2 lbs. a loss-in-weight feeder, or add weigh system should be considered.
The loss-in-weight screw feeder system will provide the highest possible
accuracies approaching ± ?(lbs. or grams), but is the most costly
and will require the most headroom of the three configurations.
An add weigh system can achieve very high accuracies based on the
volume of the weighed receptacle, and the resolution of its load cells.
However, this configuration typically consumes the most floor space
as the weighed receptacle must be supported outside of the discharger
frame (unless the mixer, blender, tank itself is the weighed receptacle
and the discharger feed device dispenses directly into it.)
Note that each of these system types are constrained by a minimum
batch dispensing time of 30 seconds. Care must be taken to ensure
proper system design to allow switching bags in mid-batch. |
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For batch sizes of over 100 lbs,
Control and Metering offers a screw feeder, or flex conveyor
integrated with one of a range of discharger models. The system
comes prewired and tested with load cells and batching control
panel. It achieves an accuracy of ±1-2 lbs per batch.
Another batching station suitable for food or pharmaceutical
applications is provided by Flo-Super Clean, the perfect bulk
bag discharging machine for situations where the operator, or
the operating environment, must have no contact with the ingredient
being discharged. The bag liner is clamped to ensure that no
dust escapes from the system. A heavy duty liner tensioner tightens
the liner to completely empty the liner of ingredient. Flo-Super
Clean with an integrated feeder provides very efficient batching,
reducing ingredient and handling costs, and delivers an accuracy
of ±1-2 lbs per batch. |
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Batching directly from a discharger using either of the two loss-in-weight
methods is extremely efficient with respect to time, capital cost
and compactness.
Direct batching from a bulk bag eliminates the need for duplication
of feed devices (vs. one feedr to empty the bag, and a second to measure
the batch at the process.) thereby reducing equipment cost and maintenance
requirements and improving reliability.
Dispensing the batch at the discharger station can reduce process
cycle times and system operating complexity.
As well, the bulk bag direct batching station is a compact, self-contained
system which can be positioned either close to, or distant from the
process thereby providing greater layout and operational flexibility.
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