Liquid Batching System
Precision Weigh-Based Proportioning for Multi-Liquid Formulations
The Indus Liquid Batching System is a custom-engineered solution designed for accurate proportional mixing of two or more liquids by weight. Ideal for industries requiring precise formulation—such as chemicals, pharmaceuticals, food & beverage, and cosmetics—this PLC-controlled system ensures consistent product quality batch after batch. Using high-sensitivity load cells and pneumatically actuated valves, it delivers exceptional accuracy from micro-batches to large industrial volumes.
How It Works
- Recipe Setup – Operator enters target weights for each liquid via HMI.
- Sequential Dosing – PLC opens valves in sequence; each liquid flows into weigh tank.
- Real-Time Monitoring – Load cells continuously transmit weight data to controller.
- Precision Cut-Off – Controller closes valve at pre-set weight (coarse/fine feed logic).
- Repeat for All Liquids – Process continues until all components are added.
- Discharge – Mixed batch is discharged via bottom valve to downstream process.
- Cycle Reset – System tares and prepares for next batch.
Technical Specifications
| Feature | Specification |
|---|---|
| Batch Capacity | 10 ml – 10,000 litres (customizable) |
| Weighing Accuracy | ±0.1% FSR (Full Scale Range) |
| Number of Ingredients | 2 to 12+ (as required) |
| Control System | PLC with Touchscreen HMI (4″ / 7″ / 10″) |
| Valve Types | Pneumatic ball valves / Butterfly valves (actuated) |
| Valve Control | Coarse / Fine feed logic for high accuracy |
| Weighing Sensors | High-sensitivity compression / tension load cells |
| Tank Construction | SS 304 / SS 316 (food/pharma grade) |
| Power Supply | 415V / 230V, 3 Phase / 1 Phase, 50 Hz |
| Air Supply | 6 bar, clean & dry |
Key Features
- High-Precision Weighing
Advanced load cells with ±0.1% FSR accuracy ensure exact formulation every batch. - PLC-Based Control
Fully automatic sequencing with recipe storage, batch counting, and fault diagnostics. - Dual-Feed Valve Control
Coarse feed for bulk flow + fine feed dribble for precise cut-off minimizes overshoot. - Touchscreen HMI
User-friendly interface for recipe management, manual override, and production reports. - Flexible Valve Configuration
Pneumatic ball valves or butterfly valves selected based on liquid viscosity and flow rate. - Sanitary Design
SS 316 contact parts, polished surfaces, and CIP compatibility for food/pharma applications. - Modular & Scalable
Expandable to add more ingredients or increase batch size as production grows.
Applications
- Chemical Industry: Acid dilution, polymer mixing, additive blending
- Pharmaceuticals: Syrup preparation, liquid oral formulations, reagent mixing
- Food & Beverage: Syrup batching, juice blending, flavor mixing, edible oil blending
- Cosmetics & Personal Care: Lotion mixing, shampoo formulation, perfume blending
- Paints & Coatings: Resin mixing, solvent blending, pigment dispersion
- Agrochemicals: Pesticide formulation, fertilizer liquid blending
- Beverage Industry: Soft drink concentrate mixing, syrup preparation
Valve Selection Guide
| Liquid Type | Recommended Valve |
|---|---|
| Water-like, low viscosity | Pneumatic Ball Valve |
| High viscosity (oils, syrups) | Pneumatic Ball Valve (larger orifice) |
| Slurries / Suspensions | Diaphragm Valve / Butterfly Valve |
| Corrosive liquids | SS 316 / PTFE-lined valves |
| Sanitary applications | Tri-clamp ball valves |
Control & Automation Features
- Recipe Management – Store up to 100+ recipes with ingredient-specific parameters
- Auto-Tare & Zero Tracking – Ensures accuracy across batches
- Alarm & Alert System – Low level, valve fault, cycle complete notifications
- Data Logging – Batch reports with date/time stamp for traceability
- SCADA / MES Connectivity – Real-time monitoring and ERP integration
- Remote Access – Optional IoT-enabled diagnostics
- Multi-Language Support – HMI in local languages
Optional Features
- Heating / Cooling Jackets – For temperature-sensitive liquids
- Agitators / Mixers – In-tank blending during batching
- CIP (Clean-in-Place) System – Automated cleaning for sanitary applications
- Level Sensors – For inventory monitoring in supply tanks
- Pump Control – Integrated control of transfer pumps
- Printout Interface – Generate batch weight tickets
- ATEX Certification – For explosive environments
Industries Served
| Industry | Typical Applications |
|---|---|
| Chemicals | Acid batching, polymer mixing, solvent blending |
| Pharmaceuticals | Liquid orals, syrups, reagents |
| Food & Beverage | Syrup, juice, oil blending |
| Cosmetics | Lotions, creams, shampoos |
| Paints & Coatings | Resin, solvent, additive dosing |
| Agrochemicals | Liquid pesticides, fertilizers |
Why Choose Our Liquid Batching System?
✅ Exceptional Accuracy – ±0.1% ensures precise formulation & reduced waste
✅ Repeatable Quality – Every batch matches recipe exactly
✅ Flexible Capacity – From 10 ml lab-scale to 10,000 litre industrial batches
✅ Hygienic Design – Food/pharma grade options available
✅ Scalable Architecture – Add ingredients or increase capacity easily
✅ Operator-Friendly – Simple HMI with recipe storage
✅ Proven Reliability – Installed in leading chemical, food, and pharma plants
Integration Capabilities
- Upstream: Level-controlled storage tanks, transfer pumps
- Downstream: Mixing vessels, filling machines, reactors
- Inventory Management: Real-time consumption tracking
- Complete Batching Plants: Multi-tank systems with common controls
Request a Custom Batching Solution
✅ Process Analysis – Understand your formulation requirements
✅ Tank & Valve Sizing – Optimal selection for your liquids
✅ Layout Design – CAD drawings for seamless installation
✅ Factory Acceptance Test – Witness performance before dispatch
✅ Turnkey Installation – Commissioning & operator training
✅ After-Sales Support – AMC, spare parts, remote troubleshooting
📞 Call/WhatsApp: +91 98454 52906
📧 Email: indusdigitalmarketing01@gmail.com
🌐 Website: www.induscontrol.in
Batch with precision. Formulate with confidence.
