Process Weighing Systems for Production Automation
Weighing Solution and Instrumentation designs process weighing systems for production lines where material weight must be measured, controlled, batched, dosed or totalized as part of the manufacturing process. These systems are used when a normal weighing scale is not enough and the weighing operation must be connected with conveyors, tanks, hoppers, silos, feeders, valves, pumps, PLC panels, HMI screens, data logging software or plant reporting systems.
Our solutions include software based batching systems, industrial dosing systems, automatic weighing systems, recipe based material feeding systems, tank weighing automation, hopper weighing automation, silo weighing systems, check weighing systems, online weight totalizers and custom process control panels.
Software Based Batching Systems
Software based batching systems are suitable for industries where multiple ingredients or raw materials must be added according to a fixed recipe. The system can guide the operator, control feeders or valves, monitor live weight, stop feeding at the target weight and generate batch records for production traceability.
- Recipe management for different products and formulations
- Automatic or semi-automatic batching sequence
- Target weight, tolerance and correction control
- Material-wise and batch-wise production reports
- Operator prompts, alarms and interlocks
- Integration with load cells, weighing controllers, PLC, HMI and PC software
- Data logging for batch number, ingredient weight, date, time and operator details
Industrial Dosing Systems
Industrial dosing systems are used for controlled addition of powders, granules, liquids or bulk materials into a process. Depending on the material and accuracy requirement, dosing can be done by screw feeders, vibratory feeders, belt feeders, pumps, valves, gates or customized feeding arrangements. The weighing system continuously monitors the weight and controls the dosing action to reduce overfeed and improve repeatability.
WSI can provide both fully automatic dosing systems and semi-automatic manual dosing systems. In a fully automatic dosing system, the software or PLC sequence selects the recipe, starts the feeder, controls coarse/fine feed, stops at the target weight and records the completed batch. In a semi-automatic dosing system, the recipe is created in the software and the operator collects or adds the materials manually with software guidance.
For manual dosing and operator-assisted batching, the software displays the selected recipe, required ingredient, target weight, live collected weight, tolerance status and progress of the batch. It helps the operator collect the correct material in the correct quantity and warns if the material is underweight, overweight, skipped or collected outside the allowed tolerance. This is useful where full automation is not practical but recipe accuracy, traceability and operator control are important.
- Fully automatic dosing systems with feeder, valve, pump or gate control
- Semi-automatic manual dosing systems with software guided material collection
- Recipe creation and recipe selection in batching software
- Live progress monitoring for each ingredient in the recipe
- Correctness checks for material sequence, target weight and tolerance
- Loss-in-weight and gain-in-weight dosing arrangements
- Coarse and fine feed control for better accuracy
- Automatic cut-off at target weight
- Batch dosing and continuous dosing options
- Alarm output for underweight, overweight, empty hopper or feed fault
- Suitable for chemical, food, pharma, cement, plastics, minerals and manufacturing plants
Control, Software and Reporting
WSI can supply the complete control architecture according to the application requirement. A process weighing system can be built around weighing indicators, weighing controllers, PLC and HMI, PC based batching software, data logging software, network connected scales or custom electronics. The system can provide relay outputs, analog outputs, Modbus/RS-485, Ethernet, Wi-Fi, USB data transfer or customized reporting as required by the plant.
Typical software features include recipe selection, target setting, live weight display, batch start/stop, fully automatic dosing sequence, semi-automatic manual dosing guidance, ingredient progress monitoring, tolerance checking, operator login, CSV/Excel reports, Google Sheets or database logging, alarm history and printable production reports.
Applications
- Automatic batching systems for food, chemical, pharma and manufacturing plants
- Industrial dosing systems for powders, granules and liquids
- Tank weighing, hopper weighing and silo weighing automation
- Conveyor weighing and online weight totalization
- Cylinder filling systems and filling by weight
- Check weighing, rejection control and production quality monitoring
- Plant automation where weighing data is required in PLC, HMI or software
Write to us with your material, capacity, accuracy requirement, feeding method, number of ingredients, control sequence and reporting requirement. We can suggest a suitable process weighing, batching or dosing system for your plant.
