Custom Engineered Gain-in-Weight Batching Solutions

Batching stations, batch weighing of multiple ingredients, and scaling systems for multi destination batching

Gain-in-weight feeding systems are widely used to deliver bulk solids into a batch process.

In a typical batch feeding system individual volumetric feeders, each one dedicated to a single raw material or active ingredient, are employed. Each feeder delivers its material in sequence into a central collection hopper, mounted on a scale or load cells.

The weight of the receiving vessel is monitored continuously as each ingredient is added in succession. Weight measurements are compared to the setpoint for each ingredient.

When the required weight of an ingredient approaches its setpoint, the volumetric feeder goes into drible mode so to insure the feeder doesn't overshoot its target. When setpoint is reached, discharge from that feeder is stopped, and the next feeder is started.

Once all the batch ingredients have been fed into the central gain-in-weight vessel, they are discharged into a mixer or blending system, or delivered directly to the next downstream step in the process.

Gain-in-weight batching systems using volumetric feeders can typically achieve accuracies of +/- 0.5% of the full scale capacity.

When minor or micro ingredients must be added with greater precision, loss-in-weight feeders may be employed to feed these critical ingredients. In these hybrid batching systems, the loss-in-weight batch feeders can deliver accuracies of +/- 0.1 - 0.5% of batch weight setpoint.

Gain-in-Weight Batching Stations

Coperion K-Tron Gain-in-Weight Batching Stations provide flexible and economical batch prep for applications up to eight components and 100 recipes.

Batching Station Details

• Accommodates any Coperion K-Tron volumetric feeder, including single screw, twin screw, Bulk Solids Pump (BSP), or any other PID device
• Accurate, durable three-point collection hopper weighing
• Full-featured KGIW controller with automatic recipe control, multi-line alphanumeric display, configurable I/Os, integrated reports and IP65 stainless steel enclosure
• Supports connection to a PLC via Interbus-S, Profibus, or DeviceNet
• Optional supervisory link via serial line or Ethernet TCP/IP

System Elements

• KGIW system controller
• External communications
• Feeder hopper
• Feeder motor drive
• Feeder
• Collection hopper
• Weighing system
• Collection hopper discharge
• Optional discharge flow diverter
• Optional stand/support structure
• Optional feed hopper vacuum conveying system

View Batching Station Spec Sheet

Multi Destination Majors Batching

When major ingredient batching requires a single ingredient to be delivered to multiple stations (see process diagram above of a food application where batched ingredients are transfered to a mixer) or multiple ingredients delivered to a single destination, scale hoppers with specialty Aeropass™ diverter valves mounted above the scale hopper can be used. After the fluidised material is discharged from a source such as a silo or bulk bag, it will typically drop through a Aerolock™ rotary valve, through a sifter (if required), and is then metered into the conveying line by another Aerolock rotary valve. Once in the convey line, it is then transported to the Aeropass valve, located above a scale hopper.

Aeropass Principle of Operation: The Aeropass valve operates on a diverter type principle and is ideal for diverting material directly into a hopper from a conveying line. Due to the valve’s low-clearance height, it is ideal when requiring inline diverters in tight spaces. As shown in the figure below, the valve includes an internal wafer type device which allows for the discharge of material into the hopper below when activated in the correct discharge position. When the scale hopper below indicates the batch is complete based on the weight signal, the Aeropass valve can be immediately shut. This allows for the transfer of the excess material in the conveying line either to the next process or scale hopper, or back into the original source. This closed loop design results in a more efficient method of product transfer with higher product yields.

Batch Weighing with Scale Hoppers

Scale hoppers are receiving hoppers suspended on load cells for ingredient batch weighing (see diagram above). The material resides in the scale hopper until the precise weight and/or combination of materials is achieved. With the scale weighing system, weigh accuracies of +/- 0.5% of the full scale capacity can be expected. Once the desired weight has been achieved, the mixer then calls for material, a butterfly valve opens and the material in the scale hopper is discharged.