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Batch Weighning System for Rubber Industry

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  • Batch Weighning System for Rubber Industry

BATCHING

Objectives –  

  • To overcome lack of visibility in batching progress
  • To overcome lack of automotated monitoring and reporting
  • To avoid manual formulation card & revisions
  • To avoid picking wrong ingredient in receipe
  • Managing ingredient tolerances
  • To settle Operator/station efficiency/ productivity management
  • To have traceability
  • To manage changeover delays
  • For pilferage/ reconciliation
  • Quality Assurance  
  • To minimize the training costs
  • To avoid system breadwon due to calibration

Specifications

  1. Bins will be provided for storing the material made up of SS 304
  2. Bin mounting structure according to the convenience
  3. Indication lamp box structure for indication
  4. Spillage tray made of SS
  5. Material weighing trolley to weigh the material according the quantity
  6. Sequential controller for controlling the sequence of operations for weighing as per the formulations
  7. Supply of cables from main panel to junction box and junction box to field as required based on the panel position
  8. Suitable size of control panel for mounting the sequential controller, power supply, relay modules with terminal blocks with fully wired and tested.
  9. Operator station for mounting the operator display unit, pushbutton and indication lamps
  10. TFT touch screen, colour display unit for displaying the required terms
  11. Supply of suitable junction box and terminal blocks that are fully wired and tested
  12. Centralized recipe management system
  13. Creating, adding, modifying and deleting recipes up to any number
  14. Actual recipe report in PDF with date and time, stamps and batch number
  15. Maintaining a single user login with password protection
  16. Provision to plan

Traceweigh Software –

  • The heart of the batching system is Traceweigh. The advanced centralized controlling software for the batching system supporting unlimited formulas and ingredients with complete scheduling, revision history, traceability and audit of the batches.
  • It supports dispensing multiple batches at the same time
  • Supports both vertical and horizontal batching
  • Can integrate with 3rdparty ERP software (Oracle, MSSQL, API)
  • Allows user/ supervisors to access the data from batching control system in real time
  • Allows viewing & printing of historical batching
  • Unlimited data can be stored with this software
  • Traceweigh monitors key process and batching data alarm conditions
  • Provides logging and historical analysis of the data
  • Traceweigh provides easy access to data from any computer using a browser that is on the same network as the computer hosting traceweigh
  • It has flexible security system
  • Facilities to set permissions for the different roles individually with view, edit, insert with assigned job function

Advantages  –

  1. Document and accelerate recipe development
  2. Manage variability and product consistency
  3. Optimize capacity and ingredient usage
  4. Drive efficient compliant production floor
  5. Control product cost and quality
  6. Specialized weigh stations for required formulation activities

ROI benefits-

  • Customer service enhancement with proactive customer deliveries
  • Greater customer confidence with complete audit information with quality assurance
  • Real time status of targets with inventory information to get the improved productivity
  • Improved planning and coordination which helps to identify pilferage sources and reduce them at all levels
  • Reduce manpower requirement with better planning
  • Reduce label wastages / monitor label consumption
  • Direct saving with improved raw material yields

Batching Types-

  1. Standalone Batching System – Batching system with one particular weighing platform with the help of manual interference the process should be done according to the application in consideration of the space, application, requirement and the budget.

  2. Bin Batch Weighing System – According to the application this batch weighing system has a bin structure for the different recipes which will be automatic and the process will be more accurate and reduce the manpower with traceweigh software.

 

Process –

  • Vertical Batching – One particular recipe can prepare by adding all the materials in one bin for the further process with accurate weighing to reduce manpower and time.
  • Horizontal Batching – One particular recipe can prepare by weighing the materials in different pans and keep it aside for the further mixing or preparation process. Which includes individual material weighing with accuracy.
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