Weigh Batching System
Precision Proportioning for Multi-Ingredient Formulations
The Indus Weigh Batching System is a fully automated, PLC-controlled solution designed for accurate proportional mixing of two or more ingredients by weight. Whether handling grams or tons, this system ensures consistent formulation quality across batches. Ideal for industries requiring precise recipe adherence—such as ready mix concrete, ferro alloys, chemicals, animal feeds, and food products—our batching systems integrate high-precision load cells with material-specific feeding devices for reliable, repeatable performance.
How It Works
- Recipe Input – Operator enters target weights for each ingredient via HMI.
- Sequential Dosing – PLC activates feeding devices in sequence; each ingredient is dispensed into weigh hopper/tank.
- Real-Time Weighing – High-precision load cells continuously monitor weight.
- Precision Cut-Off – Controller stops feed at exact target weight (coarse/fine logic).
- Discharge – Complete batch is discharged into mixer, reactor, or downstream process.
- Cycle Repeat – System tares and prepares for next batch.
Technical Specifications
| Feature | Specification |
|---|---|
| Batch Capacity | Few grams to several tons (customizable) |
| Weighing Accuracy | ±0.1% to ±0.5% FSR (application-dependent) |
| Number of Ingredients | 2 to 20+ (scalable) |
| Control System | PLC with Touchscreen HMI |
| Weighing Sensors | High-precision compression/tension load cells |
| Weigh Vessel | Mild Steel / SS 304 / SS 316 (as required) |
| Power Supply | 415V, 3 Phase, 50 Hz |
| Air Supply | 6 bar (for pneumatic devices) |
Feeding Devices – Material-Specific Selection
For Solid Materials (Powders & Granules)
| Feeding Device | Best For | Description |
|---|---|---|
| Sector Gate | Free-flowing granules, pellets | Rotary action for controlled flow |
| Slide Gate | Coarse materials, high-capacity | Linear motion, simple & robust |
| Rotary Vane Feeder | Fine powders, metered feeding | Precision airlock & dosing |
| Screw Feeder | Cohesive powders, floodable materials | Enclosed, variable speed control |
For Liquid Materials
| Feeding Device | Best For | Description |
|---|---|---|
| Butterfly Valve | Low-viscosity liquids, large flows | Quarter-turn, minimal pressure drop |
| Ball Valve with Actuator | Most liquids, including viscous | Precise on/off control, durable |
Key Features
- High-Precision Weighing
Advanced load cell technology with digital filtering ensures ±0.1% accuracy for critical formulations. - PLC-Based Automation
Fully programmable logic controller manages sequencing, recipe storage, and fault diagnostics. - Touchscreen HMI
User-friendly interface for recipe management, manual override, batch reports, and trending. - Material-Specific Feeding
Choose from multiple feeder types to optimize flow control and accuracy for each ingredient. - Dual-Speed Filling
Coarse feed for bulk flow + fine feed dribble for precise cut-off minimizes overshoot. - Data Logging & Traceability
Batch records with date/time stamps for quality control and compliance. - Modular & Scalable Design
Expandable to add more ingredients or increase batch size as production grows.
Complete System Integration
Indus supplies complete turnkey batching systems including:
- Weigh Hoppers / Tanks – Custom-designed for solids or liquids
- Storage Silos / Tanks – With level monitoring
- Feeding Devices – Gates, valves, feeders as required
- Pneumatic Conveying Equipment – For material transfer
- Material Handling Equipment – Screw conveyors, elevators
- Control Panel – PLC with HMI and optional SCADA integration
- Structural Supports – Platform and framework
Applications
| Industry | Typical Materials |
|---|---|
| Ready Mix Concrete | Cement, aggregates, sand, fly ash, admixtures |
| Ferro Alloys | Ore, coke, fluxes, additives |
| Chemicals | Powders, granules, liquids, catalysts |
| Animal Feeds | Grains, protein meals, vitamins, minerals, oils |
| Food Products | Flour, sugar, spices, additives, liquids |
| Fertilizers | Urea, DAP, MOP, micronutrients |
| Tea Processing | Tea leaf, flavor granules, additives |
| Cement Industry | Raw meal, gypsum, slag, fly ash |
| Pharmaceuticals | APIs, excipients, binders |
| Plastics | Resins, masterbatch, additives |
Control & Automation Features
- Recipe Management – Store 100+ recipes with ingredient-specific parameters
- Auto-Tare & Zero Tracking – Ensures accuracy across batches
- Alarm & Alert System – Low level, feed fault, cycle complete notifications
- Batch Reporting – Real-time and historical production data
- SCADA / MES Connectivity – Remote monitoring and ERP integration
- Multi-Language Support – HMI in local languages
- Remote Access – Optional IoT-enabled diagnostics
Optional Features
- Weigh Bridge Integration – For bulk material receipt verification
- Moisture Compensation – Adjusts for material moisture content
- Heating / Cooling Jackets – For temperature-sensitive materials
- Mixer Integration – Direct discharge into mixing vessel
- CIP System – Clean-in-place for sanitary applications
- Printout Interface – Generate batch weight tickets
- ATEX Certification – For explosive environments
Why Choose Indus Weigh Batching System?
✅ Exceptional Accuracy – ±0.1% ensures precise formulations & reduced waste
✅ Flexible Configuration – Adapts to solids, liquids, or combination
✅ Material-Specific Feeding – Optimized for each ingredient type
✅ Scalable Design – Grow from simple to complex systems
✅ User-Friendly – Intuitive HMI with recipe management
✅ Turnkey Solutions – Complete system design & supply
✅ Proven Reliability – Installed in concrete, chemical, and food plants worldwide
Industries Served
| Industry | Typical Applications |
|---|---|
| Concrete | RMC plants, precast products |
| Ferro Alloys | Furnace charge preparation |
| Chemicals | Batch reactors, blending |
| Animal Feed | Feed mills, premix plants |
| Food | Bakery, snack, beverage production |
| Fertilizers | Granulation, blending plants |
| Tea | Flavoring, blending lines |
| Cement | Grinding aids, additive dosing |
Request a Custom Batching Solution
✅ Process Analysis – Understand your formulation requirements
✅ Feeder Selection – Optimal choice for each material
✅ Tank/Vessel Design – Sized for your batch capacity
✅ Layout Engineering – 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.
