Batch weighing hopper

Types of batch weighing hoppers

A batch weighing hopper functions as a storage vessel for various raw materials and can weigh them simultaneously. It is mostly common in the food, chemical, mining, pharmaceuticals, and construction industries. Several different kinds of batching weigh hoppers exist, each with unique features.

• Food-grade weighing hopper : This batch weighing hopper is mainly used for food purposes. It is designed to meet strict food safety requirements and is typically constructed from stainless steel, which is easy to clean and sanitize. Food-grade hoppers may also have additional features like anti-microbial coatings or smooth, flat surfaces with no crevices where food could get stuck and contaminants could grow.
• Multi-purpose weighing hopper : A multi-purpose weighing hopper is mainly used in industries where the materials are not difficult to handle. It is made from sturdy materials like steel and is capable of handling a wide range of materials, including powders, grains, and aggregates. Some multi-purpose weighing hoppers come with vibration, airflow, or mixing capabilities to improve material flow and ensure accurate weighting.
• Micro-ingredient weighing hopper : Micro weigher has multiple storage hoppers that are used to store small quantities of ingredients. The hoppers are typically made from stainless steel or food-grade plastic. The batch weighing hoppers also come with features that ensure accurate weighing with tolerance levels up to 0.5 or 0.1.
• Multi-head weigher hopper : Multi-head weighers use advanced weighing technology, such as load cells and computer-controlled weighments, to precisely measure complex mixtures at high speeds. Depending on the specific model and configuration, the accuracy of multi-head weighers can typically be within ±1 to ±2 grams.
• Open-line weighing hopper : Open-line weighing hoppers are commonly used in chemical and snack food applications. The weighing and packing happens while the line is open, allowing multiple products to be filled in a set amount of time without having to switch out products.

Specification and Maintenance of Batch Weighing Hoppers

Specifications for these weigh hoppers can vary according to the industry and application. Here are some of the key batch weighing hoppers' specifications and their maintenance requirements:

• Calibration:

  The batches or hoppers should be recalibrated at regular intervals to maintain accuracy. The calibration frequency will depend on factors like usage, environmental conditions, and weighing standards. Regular recalibration helps to ensure that the hoppers are weighing precisely in line with the set weights and measurements.

• Cleaning:

  It is important to do regular cleaning of the batch weighing hoppers. The type of cleaning approach will depend on the weigh hopper's design and the material it is weighing. Generally, a combination of dry and wet cleaning methods should be used to remove residues or any build-up material. Also, the weighing buckets or hoppers should be cleaned after every product change to avoid cross-contamination of different materials.

• Stress and Strain Analysis:

  Data from strain gauges and load cells should be analyzed regularly to identify any signs of excessive stress or strain that may affect the hoppers' structural integrity. This can include monitoring the batch weighing components' load cell output, strain measurements, and checking for any unusual patterns or changes in the data. Also, a thorough inspection should be done on the hoppers to look for signs of fatigue or damage.

• Smooth Operation:

  The moving parts of the batch weighs hoppers should be lubricated periodically to prevent wear and tear and facilitate smooth operation. The lubricating oil used should be suitable for the weighing device's material and operating conditions. Also, periodic maintenance checks should be done to ensure that all moving components are functioning properly and are in good condition.

Scenarios of batch weighing hoppers

• Food industry

  Batch weighing hoppers are extensively used in the food industry for precise ingredient proportions during food processing and cooking. They can be used for weighing and measuring ingredients like sugar, flour, and spices, ensuring consistency, quality control, and compliance with food safety regulations.

• Agriculture industry

  In agriculture, batch weighing hoppers can be used for fertilizers, pesticides, seeds, and animal feed weighing and measuring. They enhance accuracy in batches, support efficient production, and enable effective resource management.

• Chemical industry

  In the chemical industry, batch weighing hoppers are used for measuring and mixing chemicals, additives, and pigments. They support precision in formulations, quality control, and consistency in production.

• Construction industry

  In the construction industry, batch weighing hoppers can be used for materials like cement, aggregates, and additives weighing and measuring. They ensure accurate proportions in concrete mixes, improve material utilization, and support quality in construction projects.

• Plastic industry

  In the plastic industry, batch weighing hoppers are used for measuring and feeding resin, additives, and colorants. They ensure accuracy in plastic production, support uniformity in product quality, and enhance process efficiency.

• Pharmaceutical Industry

  In the pharmaceutical industry, batch weighing hoppers can be used for precise measurement of ingredients like active pharmaceutical compounds, excipients, and fillers. They support accuracy in drug formulations, quality control, and compliance with regulatory standards.

How to Choose Batch Weighing Hopper

• Industry Requirements:

  Understand the specific needs of the industry applications, such as the precision and capacity of material weighing in the food, chemical, pharmaceutical, or other industries. Also, consider the batch weighing hopper's compliance with industry standards and regulations.

• Material:

  Select a material with durability and corrosion resistance for the weighing hopper, such as stainless steel or a specific alloy, to meet the requirements of different materials and ensure its service life.

• Weighing System:

  Choose an appropriate weighing system and sensors based on accuracy and capacity requirements. Consider factors such as sensor sensitivity, calibration methods, and data processing systems to ensure the selected system can provide the desired precision and reliability.

• Control System:

  Determine the control functions and automation levels needed for batch weighing and select a suitable control system to manage the operation and control of the weighing hopper. This may include selecting a programmable logic controller (PLC), human-machine interface (HMI), and other control components.

• Integration Requirements:

  If necessary, consider the integration of other production equipment and systems, such as the connection and coordination with feeders, mixers, data acquisition systems, etc. Ensure the selected batch weighing hopper can be well integrated into the entire production line.

• Safety and Maintenance:

  Pay attention to the safety features of the batch weighing hopper, such as electrical safety, explosion-proof properties, etc., and ensure the chosen hopper complies with relevant safety standards. Additionally, consider maintenance and accessibility for cleaning and repairs.

Batch weighing hopper FAQ

Q1: What are the differences between batch and continuous weighing hoppers?

A1: A batching weighing hopper is used to estimate the material's weight, while a feeding hopper conveys the estimated material continuously. Batching weighing hoppers can be used for various purposes and are easy to clean. Feeding Hoppers are used primarily in production processes that require granules or particles.

Q2: Why is batch weighing more accurate?

A2: Batching weighing is more precise as it involves multiple small weights instead of one large weight. This improves precision by reducing the likelihood of rounding errors.

Q3: What are the two techniques of batch weighing?

A3: The two techniques for batch weighing include direct weighing and incremental weighing. Direct weighing involves measuring the entire batch simultaneously, while incremental weighing measures individual quantities sequentially.

Q4: Is batch weighing hopper different from the continuous weighing hopper?

A4: Yes, batch weighing hoppers differ from continuous weighing hoppers. A batch weighing hopper measures the weight of batches at specific intervals. In contrast, a continuous weighing hopper measures the weight of materials at a constant flow rate continuously.