Automatic batching system ( Automatic Batching System ) is the core equipment used in modern industrial production to achieve precise measurement, mixing, and conveying of raw materials. Depending on differences in process principles, material forms, measurement methods, and application industries, it can be categorized into various types.

The following is a detailed classification of automatic batching systems and their primary applications:

I. Classification by Measurement Method (Core Classification)

This is the most technically sophisticated classification method, directly determining the precision and speed of ingredient dispensing.

1.  Weightless batching system (Loss-in-Weight)

Principle: The feeding rate is controlled by continuously monitoring the decrease in the hopper’s weight. The controller dynamically adjusts the rotational speed of the screw or vibrating feeder based on the rate of weight change.

Features: Extremely high precision (up to 0.1%~0.5% ), highly consistent and suitable for trace addition.

Usage:

Plastic modification / Granulation: Continuous co-mixing of the main material with color masterbatches and additives.

Food / Feed: Continuous addition of micronutrients such as vitamins and enzyme preparations.

Chemical extrusion: A continuous production line with extremely strict requirements for formulation ratios.

2.  Incremental batching system (Gain-in-Weight)

Principle: First, weigh the empty container. Then, add material into the container until it reaches the target weight, at which point you stop adding material. This can be done either with a single scale and multiple ingredients (adding ingredients one by one) or with multiple scales and multiple ingredients (adding ingredients simultaneously).

Features: Relatively simple structure, suitable for batch production, high precision, but speed is limited by the feeding time.

Usage:

Friction material / Refractory materials: Multi-component, large-batch batchwise mixing (such as the mobile-cart type commonly used by Wuxi Xielì).

Concrete / Mortar: A bulk mixture of sand, gravel, and cement.

Rubber compounding: Batch weighing of carbon black, oil, and raw rubber.

3.  Volumetric batching system (Volumetric)

Principle: The material volume is estimated by controlling the rotational speed or duration of the feeding device, assuming a constant material density.

Features: Low cost and fast speed, but accuracy is greatly affected by fluctuations in material density (accuracy typically ranges around...). 1%~5% ).

Usage:

Coarse ingredients with low precision requirements.

Particulate materials with excellent flowability and stable density (such as certain plastic pellets).

Typically used as a low-cost, weightless alternative or for the pre-mixing of non-critical components.

II. Classification by Material Form and Conveying Method

1.  Powder batching system

Features: It needs to address issues such as dust generation, bridging (arching), and static electricity. It is often equipped with dust removal and arch-breaking devices.

Conveying methods: screw conveyor, pneumatic conveying, vacuum feeding.

Applications: Flour processing, cement production, positive and negative electrode materials for batteries, pigments and dyes, friction materials (graphite) / Resin powder).

2.  Particle / Bulk Ingredient System

Features: The challenge lies in addressing the issues of material crushing and classification (separating particles by size).

Conveying methods: belt conveyor, vibratory feeder, gravity flow.

Uses: Aggregate (sand and gravel), plastic pellets, grain cereals, and ingredients resulting from the crushing of ores.

3.  Liquid ingredient system

Features: Requires addressing viscosity differences, flowmeter calibration, and pipeline cleaning issues.

Delivery method: gear pump, screw pump, flowmeter control.

Use: Coatings and inks (resin) / Solvent), food and beverage (syrup) / Flavoring), pharmaceuticals (pharmaceutical liquid mixing).

4.  Solid -  Liquid Mixing and Dispensing System

Features: It can handle both solids and liquids simultaneously; the process is complex and requires careful coordination of the order in which solids and liquids are added.

Applications: Production of concrete admixtures, blending of high-end lubricating oils, and production of compound fertilizers (spray granulation).

3. Classification by Automation Level and Control Mode

1.  Manual / Semi-automatic batching

Description: Manual material feeding or manual button activation; the instrument displays the weight, and manual judgment is used to determine when to stop.

Applications: Small-batch prototyping, laboratory R&D, and the transition period for upgrading aging factories.

2.  Fully automatic batch batching

Description: PLC Control the entire process (material requisition) -> Weighing -> Discharge material -> Cleaning), requiring no manual intervention and automatically recording data.

Applications: Standard equipment in the vast majority of modern chemical plants (e.g., friction materials, feed mills).

3.  Continuous dynamic batching

Description: Materials are measured and mixed in real time during the conveying process, with no noticeable “batch” interruptions.

Applications: Raw material preparation for large-scale cement plants, long-distance coal transportation via belt conveyors, and large-scale plastic extrusion lines.

4.  Smart Network Ingredient Dispensing (MES/ERP Integration )

Description: The system is networked, with recipes transmitted from the host computer and data uploaded in real time. It supports barcode-based error prevention, quality traceability, and remote operation and maintenance.

Applications: Industries with stringent requirements for quality traceability (pharmaceuticals, food, automotive components, and export-oriented friction material manufacturers).