Load Cell Batching Scale System Electronics
In this article I will be going over the basics of the WINOX-2G (similar functionality as with the WDOS and other WINOX displays) using the pre-programmed weighing modes: Load, Unload, or Multi-Ingredient. These three weighing modes can be used for batching scales in manual or automated applications.
Accuracy of your filling, discharging or multiple ingredient recipes is critical. Controlling your weighing system more precisely with the proper load cell electronics not only improves quality and inventory numbers, but also reduces waste.
The WINOX-2G has many available options including: analog output, WiFi, panel mount enclosure, and large scoreboards to aid in manual batching. The load cell controller stores crucial data such as the number of batching cycles, amount of product used, and total weight values. Also available is the USB and serial transfer of the batch weighing data. The USB option allows you to plug in a thumb drive and download the data, the serial option allows transfer of the same information. Database software is provided to import and view the information on a PC (when you choose of these options).
Now let’s dive into the three different available batching programs.
LOAD Weighing Mode
Fill to a setpoint mode, allows control of filling a container by weight. Applications can include: bag, pale, drum, tote filling scales. The container is placed on a pre-made scale base, or a custom load cell setup.
A company that fills large totes with fish needed to accurately control the filling process. Equipment needed: stainless steel floor scale, and the WINOX-2G load cell indicator.
The process is simple; the operator enters a formula (setpoint value) or chooses from up to 99 stored formulas from the keypad. The batch controller then performs a tare function to remove the weight of the container on the scale. The Start button is pressed causing a relay output to turn on, which opens the gate on the bulk storage tank containing the fish. The unit fast fills to a setpoint then closes the gate. The customer chose to enable the Tapping feature that opens and closes the gate quickly until the final setpoint is reached (this ensures the highest accuracy the final weight). The tote is removed and replaced with an empty one, and then the process is repeated.
UNLOAD Weighing Mode
Dispense to a setpoint or loss in weight mode, unloading a scale to a certain weight value. Applications could include dispensing product from a bulk or mixing tank that is being weighed.
A precast cement company weighs a hopper using load cells under the legs of the vessel and the WINOX-2G programmable indicator. The application requires the operator to choose a weight value of product to dispense into the forms. Their process has six forms of the same size to fill. The operator chooses the weight value and the number of dispensing cycles (six in this case), and presses the Start button. The WINOX-2G controller opens a valve to start dispensing cement into a form, the relay is closed once the scale reaches the desired setpoint. The wait time between cycles is selectable, they chose to wait 10 seconds before the next filling takes place. The digital display will also not allow the batch process to start if there is not enough product in the hopper to complete the process.
MULTI-INGREDIENT Weighing Mode
This weighing mode allows filling of multiple ingredients (there is a that allows for up to 3, 6, or 14 ingredient version). The tank is supported by a load cell system, and connected to the indicator. Each ingredient’s name is entered into the WINOX-2G. The operator then creates a recipe using the ingredients needed and the weight values for each. The order of the filling process can also be altered as needed.
A food company is making ketchup, and they have an existing mixing tank. The tank is supported by load cells and connected to the WINOX-2G scale controller. Their process requires a combination of automated and manual filling. The tomato pulp, sweetener, and salt are added automatically using the relay controls from the batching indicator. When this first process is completed, the remaining ingredients are weighed on a smaller capacity bench scale and added to the batch. The WINOX-2G has the option installed to send the batch information to a PC in the control room. There they can track each batch for quality and inventory usage.
Batch Weighing using the WINOX-2G Indicator Conclusion
This series batch weighing controller can work in conjunction with a PLC or often times eliminate the need for a PLC. Entering ingredients and recipes is intuitive and user-friendly. Once setup it’s as easy as entering a formula ID and pressing the Start key.