Flexicon weigh batching systems offer a highly versatile solution for precise ingredient handling across a wide range of applications. Whether you’re working with single or multiple ingredients, sourcing from silos, bulk bags, or manual dump stations, Flexicon systems are designed to accommodate your process with accuracy and efficiency.
They support thorough blending of multi-ingredient batches and ensure reliable delivery to downstream operations, maintaining consistency and throughput. Including fully integrated and automated controls, Flexicon’s comprehensive approach provides a complete batching solution that simplifies operations and enhances productivity from start to finish.
Gain-in-weight batching systems
Flexicon gain-in-weight batching systems offer precise ingredient handling by conveying bulk materials mechanically or pneumatically from any location to a central receiving vessel mounted on load cells. This vessel can be a hopper positioned above a blender, reactor, or other process equipment—or it can be the equipment itself. When a batch is initiated via manual start or automated signal, a programmable controller activates the first flexible screw conveyor or rotary airlock valve to load the initial ingredient at full feed rate. As the vessel gains weight, load cells transmit data to the controller, which gradually reduces the feed rate to a dribble for enhanced accuracy. The system then stops the conveyor just before reaching the target weight to account for material in transit, ensuring precise batching every time.
Flexicon bulk bag loss-of-weight batching systems provide a highly accurate and efficient method for batching bulk materials. Each system features a material source, such as a Flexicon bulk bag discharger with conveyor, mounted on load cells that measures weight loss during the batching cycle and relays this data to a system controller. The batching process begins with a manual start or automated signal, prompting the conveyor to unload material at full feed rate. As the batch progresses, the controller uses real-time weight loss data to reduce the feed rate to a dribble before stopping the conveyor when the target weight is reached. The automation controls also support mid-batch bulk bag changes and can include multiple dischargers, each conveying different ingredients to a central point such as a hopper, blender, reactor, or other process equipment.
Explore the features of Flexicon Weigh Batching Systems
Mounted on precision load cells, the Gain-In-Weight Receiving Hopper transmits real-time weight data to a load cell controller incorporated into a custom automation control center. This enables automated loading of each ingredient in sequence by starting/stopping conveyors or opening/closing valves. Simultaneous blending of one batch while weighing the next reduces cycle times and boosts throughput.
The PLC automates the entire batching and blending process from valve actuation and mixer operation to ingredient conveyor control. Conveyors operate at high feed rates for cycle time optimization, then transition to dribble feed for precise ingredient delivery, streamlining the process for efficiency and accuracy. Upon completion of the ingredient loading process, the controller opens the discharge valve of the Gain-In-Weight Hopper, releasing ingredients into the blender and resetting to weigh the next batch.
Flexicon’s Weigh Batching Systems are designed to integrate with both new and existing mixers and blenders, offering unmatched flexibility and performance. Compatible equipment includes Ribbon Blenders, Paddle Blenders, Plow Blenders, Vee-Cone Blenders, Fluidized Bed Mixers, Rotary Drum Mixers, making it easy to upgrade or expand your batching capabilities without disrupting your current operations.
Whether feeding process equipment, packaging lines, or storage vessels, Flexible Screw Conveyors, Tubular Cable Conveyors, and Pneumatic Conveying Systems deliver reliable, dust-free downstream transport of the batch compatible with your process needs.
Flexicon weigh batching systems offer a range of advantages to improve your bulk handling processes.
Reduced Labor Costs
By automating the weighing and delivery of bulk material ingredients, the system eliminates time-consuming manual weighing, reducing the need for skilled labor. This allows workers to focus on higher-value tasks, such as system oversight or quality control, resulting in significant cost savings and increased productivity.
Reduced Material Waste
Precise control over ingredient quantities minimizes overuse and reduces product loss, especially important for costly or sensitive materials.
Bulk Container Purchases
Purchasing bulk materials in larger containers, such as bulk bags, reduces costs by lowering per-unit material prices and minimizing packaging waste.
Improved Product Quality
Flexicon’s automated weigh batching systems deliver precise, repeatable ingredient measurements every time. By eliminating manual measurement, the system ensures consistent batch quality, reduces formulation errors, and helps maintain product integrity - batch after batch. This level of accuracy is especially critical for applications where even slight variations can impact performance, safety, or customer satisfaction.
Increased Productivity
With fully automated weighing and batching, your operation moves faster and more efficiently. The system controls every step, from ingredient delivery to final blending, cutting down on manual labor and reducing downtime between batches. This means shorter cycle times, higher throughput, and the ability to meet growing production demands without compromising quality.
Dust and Contamination Control
Designed with safety and cleanliness in mind, Flexicon systems feature enclosed material handling and process connections that minimize dust emissions. This not only protects your product and equipment, but also creates a healthier work environment for your team, especially important in industries with strict hygiene or safety standards.
Scalability and Customization
Flexicon weigh batching systems deliver superior scalability and customization. A seasoned team of applications and mechanical design engineers create physical equipment layouts and designs to meet any facility's unique process requirements. Additionally, a skilled team of automation engineers provides highly customized controls that can be easily adapted as customer requirements evolve, supporting complete integration and future scalability.
Flexicon can design your weigh batching system to meet your unique needs. Explore some of the configurations we have developed for customers like you.
– Tony Swann, Safety, Health & Environment Manager at Welcome Food Ingredients
– Hiram Carlo, Plant Manager at Sazon, Inc., a manufacturing division of GOYA Foods
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