Weigh Batching Systems

Flexicon weigh batching systems offer a highly versatile solution for precise
ingredient handling across a wide range of applications. Whether you’re
working with single or multiple ingredients, sourcing from silos, bulk bags, or
manual dump stations, Flexicon systems are designed to accommodate your
process with accuracy and efficiency.

They support thorough blending of multi-ingredient batches and ensure
reliable delivery to downstream operations, maintaining consistency and
throughput. Including fully integrated and automated controls, Flexicon’s
comprehensive approach provides a complete batching solution that simplifies
operations and enhances productivity from start to finish.

Product Overview

Learn everything you need to know about Flexicon Weigh Batching Systems.

Gain-in-weight batching systems

Flexicon gain-in-weight batching systems offer precise ingredient handling by conveying bulk materials mechanically or pneumatically from any location to a central receiving vessel mounted on load cells. This vessel can be a hopper positioned above a blender, reactor, or other process equipment—or it can be the equipment itself. When a batch is initiated via manual start or automated signal, a programmable controller activates the first flexible screw conveyor or rotary airlock valve to load the initial ingredient at full feed rate. As the vessel gains weight, load cells transmit data to the controller, which gradually reduces the feed rate to a dribble for enhanced accuracy. The system then stops the conveyor just before reaching the target weight to account for material in transit, ensuring precise batching every time.

LOSS-OF-WEIGHT batching systems

Flexicon bulk bag loss-of-weight batching systems provide a highly accurate and efficient method for batching bulk materials. Each system features a material source, such as a Flexicon bulk bag discharger with conveyor, mounted on load cells that measures weight loss during the batching cycle and relays this data to a system controller. The batching process begins with a manual start or automated signal, prompting the conveyor to unload material at full feed rate. As the batch progresses, the controller uses real-time weight loss data to reduce the feed rate to a dribble before stopping the conveyor when the target weight is reached. The automation controls also support mid-batch bulk bag changes and can include multiple dischargers, each conveying different ingredients to a central point such as a hopper, blender, reactor, or other process equipment.

Product Features

Explore the features of Flexicon Weigh Batching Systems

GAIN-IN-WEIGHTRECEIVING HOPPER

Mounted on precision load cells, the Gain-In-Weight Receiving Hopper transmits real-time weight data to a load cell controller incorporated into a custom automation control center. This enables automated loading of each ingredient in sequence by starting/stopping conveyors or opening/closing valves. Simultaneous blending of one batch while weighing the next reduces cycle times and boosts throughput.

AUTOMATION CONTROLS

The PLC automates the entire batching and blending process from valve actuation and mixer operation to ingredient conveyor control. Conveyors operate at high feed rates for cycle time optimization, then transition to dribble feed for precise ingredient delivery, streamlining the process for efficiency and accuracy. Upon completion of the ingredient loading process, the controller opens the discharge valve of the Gain-In-Weight Hopper, releasing ingredients into the blender and resetting to weigh the next batch.

MIXER/BLENDER INTEGRATION

Flexicon’s Weigh Batching Systems are designed to integrate with both new and existing mixers and blenders, offering unmatched flexibility and performance. Compatible equipment includes Ribbon Blenders, Paddle Blenders, Plow Blenders, Vee-Cone Blenders, Fluidized Bed Mixers, Rotary Drum Mixers, making it easy to upgrade or expand your batching capabilities without disrupting your current operations.

VERSATILE DOWNSTREAMCONVEYING OPTIONS

Whether feeding process equipment, packaging lines, or storage vessels, Flexible Screw Conveyors, Tubular Cable Conveyors, and Pneumatic Conveying Systems deliver reliable, dust-free downstream transport of the batch compatible with your process needs.

Product benefits

Flexicon weigh batching systems offer a range of advantages to improve your
bulk handling processes.

Reduced Labor Costs

By automating the weighing and delivery of bulk material ingredients, the system eliminates time-consuming manual weighing, reducing the need for skilled labor. This allows workers to focus on higher-value tasks, such as system oversight or quality control, resulting in significant cost savings and increased productivity.

Reduced Material Waste

Precise control over ingredient quantities minimizes overuse and reduces product loss, especially important for costly or sensitive materials.

Bulk Container Purchases

Purchasing bulk materials in larger containers, such as bulk bags, reduces
costs by lowering per-unit material prices and minimizing packaging waste.

Improved Product Quality

Flexicon’s automated weigh batching systems deliver precise, repeatable ingredient measurements every time. By eliminating manual measurement, the system ensures consistent batch quality, reduces formulation errors, and helps maintain product integrity – batch after batch. This level of accuracy is especially critical for applications where even slight variations can impact performance, safety, or customer satisfaction.

Increased Productivity

With fully automated weighing and batching, your operation moves faster and more efficiently. The system controls every step, from ingredient delivery to final blending, cutting down on manual labor and reducing downtime between batches. This means shorter cycle times, higher throughput, and the ability to meet growing production demands without compromising quality.

Dust and Contamination Control

Designed with safety and cleanliness in mind, Flexicon systems feature enclosed material handling and process connections that minimize dust emissions. This not only protects your product and equipment, but also creates a healthier work environment for your team, especially important in industries with strict hygiene or safety standards.

Scalability and Customization

Flexicon weigh batching systems deliver superior scalability and customization. A seasoned team of applications and mechanical design engineers create physical equipment layouts and designs to meet any facility’s unique process requirements. Additionally, a skilled team of automation engineers provides highly customized controls that can be easily adapted as customer requirements evolve, supporting complete integration and future scalability.

Weigh Batching System Configurations

Flexicon can design your weigh batching system to meet your unique needs. Explore some
of the configurations we have developed for customers like you.

Bulk Bag Weigh Batch Unloader with Seismic Bracing

Pneumatic Weigh Hopper with
Fill/Pass Valve

Sanitary Bulk Bag Weigh Batch
Unloader

Re-Bagging Of Granular Sugar Improved With Bulk Bag Weigh Batch Discharger

The company now accomplishes tasks in one-third less time with less labour while meeting ATEX requirements using an automated bulk bag weigh batching system with integral flexible screw conveyor from Flexicon Europe.

"The fact that Flexicon could supply an ATEX-rated food quality handling system was of great importance to Welcome Food Ingredients."

– Tony Swann, Safety, Health & Environment Manager at Welcome Food Ingredients

Automated Weigh Batching Increases Output, Ends Fatigue at Goya Florida

Before Flexicon, workers previously loaded herbs, spices, salt and seasonings manually into three ribbon blenders, each with a working capacity of nearly 3,000 lb (1,360 kg). The job required lifting, cutting, and dumping several dozen bags per batch, for 21 batches over an eight-hour shift.

“We package more than a billion packets a year now, and we're much more comfortable."

Hiram Carlo, Plant Manager at Sazon, Inc., a manufacturing division of GOYA Foods