Raw Material Intake Automation
Intake is started by selecting raw material, destination-1, destination-2. System starts intaking into destination-1. System continues with destination-2 when destination-1 is full.
Each intake is tagged with date, time and supplier id for traceability purposes.
Filling a silo can be done at the same time as dosing from this silo. Stock control is done by adding what goes in (manually), deducting by dosing scale what goes out and Correction is always possible. Contents of the silos will be visualized.
Dosing Automation Principles
Batch is calculated using formula/recipe. Items/rawmetarials are grouped into weighing groups: Example: macro dosing weigher 1, macro dosing weigher 2, micro dosing weigher, fat weigher, molasses flowmeter, hand-tipping. Weighing groups are run in parallel as much as possible. Example: macro dosing weighing, micro dosing weighing and fat weighing are started as soon as route is available. In a weighing group, if possible, parallel weighing is used also. Example: an item/rawmaterial exists in more than one silo and those silos are in one group. In this case dosing system takes item/rawmaterial from all those silos in parallel. Each batch is tagged with a unique id. All the elements (bunker, hammer mill, mixer…) in the route indicate the batch id its processing. Database records and reporting are based on batch id. This is important for traceability. Time required to process the batch on each element (weigher, hammer mill, mixer…) on the route are recorded and reported. Automatic after flow correction is performed for each weighing. Tolerance is monitored for each weighing. Dosing results are recorded and reported for each batch.
Dosing start window is shown below. Dosing is started by defining recipe, destination silo, batch amount (kg) and number of batches to be produced.
For not continues dosing processes, each dosing group (dosing, micro-dosing, liquids…) starts dosing in parallel. They are synchronized before going into the mixer.
For hand-tipping a flashlight indication is given to the personnel responsible for emptying the material.
There are three hand-tip locations in the line
1- Before hammer mill on ground floor,
2- In micro-dosing scale,
3- Directly in mixer (medicines, limestones etc.).
The procedures for adding the right hand-tip at the right moment is very important. Now in order is only button for acknowledgement. Alternative (not in order now) is to secure this by barcode scanning and acknowledge button. Plant Manager already has barcode scanning in the software.
Silos can be excluded from dosing.
If material finishes during dosing then a timeout occurs and operator is warned. Operator then has two options:
- a) Abort current batch, manually move materials already dosed to another location.
- b) Fill up the empty silo and continue dosing.
The system does not allow to continue without dosing each item in the recipe.
If a raw material exists in more than 1 silo then dosing is split equally among those silos.
Content of silos are visible on HMI (Human Machine Interface).
Historical ins and outs of each silo is reported for traceability purposes.
Error and correction calculations are performed after each dosing and system corrects itself to achieve high dosing accuracy.
If dosing and micro-dosing screws are driven by VFD’s, system controls the screw speed to achieve high dosing accuracy.
Result of dosing for each batch is recorded in database and reported.
Emptying a silo (in case of emergency) can only be done on manual mode via the hammer mill (with screens out) and via mixer and bypass molasses mixer directly to FP silo.
Starting up a line always will start with the last machine in the line. Stopping will start with the first machine in the line. 20-5-2016 In addendum 3 was added a flat box but not shown on the diagram.
For escape Feed Tech will offer a flat box 45 degrees, manually controlled under the Chain conveyor under the dosing scale.
▶Maximum parallel weighing
▶ Unlimited number of weighing groups
▶ Unlimited number of rawmaterials/items
▶ Unlimited number of formula/recipe
▶ After flow correction
▶ Wide variety of supported mechanics
▶ Batch or continues dosing
▶ Conforms to traceability
▶ ERP integration Application Areas
▶ Feed mills
▶ Additive production
▶ Any process involving dosing of flowable materials Supported mechanics
▶ Speed controlled screw conveyor
▶ Grid slides
▶ Liquid pumps
▶ Weighers with load cells
▶ Liquid and solid flowmeters