Accurate weighing and dosing have emerged as fundamental components within the chemical processing industries, particularly as companies seek to ensure product quality, safety, and resource efficiency. Experts highlight that innovations in technology, automation, and intelligence are paving the way for enhanced precision in weighing operations, a development that is crucial for various sectors including food, pharmaceuticals, and battery manufacturing.

Joe Schobel, a sales engineer at AZO, emphasises the significance of precise ingredient weighing, stating, “Each ingredient’s proportion within a mixture contributes to the product’s finished quality, so any deviation can offset the delicate balance of a precise formulation.” Keith Melton, the sales manager for the battery industry at Coperion K-Tron, concurs, pointing out that “high feeding accuracy is of paramount importance in a range of chemical manufacturing applications.” He notes that maintaining precise proportions not only ensures consistency but also enhances efficiency and mitigates safety risks associated with incorrect ingredient proportions.

Despite the obvious benefits, industry experts acknowledge that achieving high-accuracy weighing performance is fraught with challenges. Vibrations from surrounding equipment can considerably affect weighing accuracy, as Melton explains. To counter these issues, companies are developing innovative solutions designed to improve measurement reliability. Coperion has introduced the Smart Force Transducer (SFT) technology alongside KCM feeder control modules. According to Melton, the SFT technology ensures precise measurements, essential for maintaining productivity and reducing waste.

Hardy Process Solutions has also tackled the challenge of vibration with its 6850 weight controller, which features dual-core processing. Tim Norman, a senior product development manager at Hardy, articulates the unique engineering behind this system: “One core can be used to run an application, while the other is dedicated to digital signal processing, eliminating the effects of mechanical vibrations on a scale system.”

Additionally, advancements in automation are leading to substantial improvements in weighing accuracy, especially in the context of minor and macro dosing. The Componenter system developed by AZO automates the weighing and dosing process, significantly reducing errors associated with manual operations, and allowing for faster throughput. Nicole Werner from Zeppelin Systems elaborates on their Automated Small Components Weighing System, which caters to the rubber and tyre sectors, demonstrating the capacity for fully automated weighing even with varying densities of materials.

The importance of accuracy is particularly pronounced in the fast-growing battery production sector, wherein any fluctuations may jeopardise end-product quality and lead to increased waste. Melton details the need for precise ingredient addition, particularly in the context of dry coating applications, where consistent material distribution is essential.

Lab environments are also witnessing enhancements through innovations in weighing technology. Products like Sartorius’s Premium Lab Balance Cubis II Portfolio are equipped with advanced sensors that adjust for environmental factors impacting measurement accuracy. Lucas Foerster from Sartorius notes that newer balances can alert users when conditions might compromise results, thus ensuring more reliable performance.

Automation not only streamlines weighing processes but also enhances overall production efficiency. Norman asserts that modern equipment is capable of responding to changes in weight data within seconds, facilitating immediate operational adjustments, such as valve control. This leads to reduced waste, improved product quality, and the ability to operate continuously, thus maximising productivity.

Coperion's Melton further highlights the value of intelligent controllers which can learn from operational data, thereby optimising processes and pre-emptively managing unexpected events that could disrupt weighing accuracy. This integration of past performance and real-time monitoring presents a significant advancement, reflecting an industry-wide shift towards smarter and more adaptable systems.

As weighing technologies evolve, they are not only tailored for enhanced accuracy but also for improved flexibility, catering to varying production needs and changes in material characteristics. The ongoing trend is indicative of a broader market shift towards automation and intelligence in manufacturing processes, where precision remains paramount in ensuring product quality and operational efficiency.

Source: Noah Wire Services