Bulk Bag Resupply of Batching System

Bulk Bag Resupply of Batching System

Bulk bag resupply of batching system: When you need to resupply you micro batching system with ingredients that come in bulk bags, Sterling Systems has the answer, and here is a great example. Feeding poultry on a mass scale to promote egg production along with needing the flexibility in manufacturing feed with varying formulations to meet production demands necessitates a micro ingredient batching system with high throughput and production capacity. Integrating bulk bag resupply bins in the batching system is essential.

Most often micro ingredient batching system bins are resupplied by small bag, e.g. 25lb, 25kg, etc. and this is done manually by an operator.  Ingredient lot tracking, important in many industries, is easily accomplished using optional locking lids, RFID scanning, Barcode scanning or operator manual entry of ingredient lot data to print labels and enter for bin resupply. However, periodically ingredients are purchased in “bulk”, often 1000lbs or more at a time in a single “bulk bag” or FIBC (flexible intermediate bulk container).  When bulk bags are to be integrated in a micro ingredient batching system, this requires expertise in both bulk bag discharging or unloading AND batching and material weighing systems.  Sterling Systems & Controls uniquely brings the combination of expertise in weighing, batching systems, process equipment, bulk bag unloading, process controls and automation to be able to custom engineer and manufacture the best micro ingredient batching system using bulk bags for ingredient bin resupply.

Example Application
Funnel showing closed dust takeoff for dust collector connection

Feed production for an egg farm required a twenty-four (24) bin micro ingredient batching system. Eight (8) of the bins would enclose ingredients that are supplied from FIBC’s (bulk bags).  Custom engineering the system Sterling Systems integrated its bulk bag discharging equipment and controls to handle this.  The bulk bag unloading system consists of the following features:

  1. Bag hoist
  2. Heavy duty frames to support bulk bags
  3. Bulk bag funnel with door access to untie bags in order to reduce dust and provide for operator safety

The overall system was custom engineered and included the following:

  • Twenty-four (24) micro supply bins, each with about 200lbs capacity
  • Eight (8) integrated bulk bag unloading stations
  • Four (4) micro scale hoppers
  • Sixteen (16) 3″ auger type feeders
  • Eight (8) 4″ auger feeders (for bulk bags)
  • Stainless steel construction for contact metal
  • Painted mild steel for non-contact metal
  • Typical batch size is 8,000lbs
  • Batch time is 2-3 minutes
  • Controls

The system reduces the handling of the ingredients, ensure the ingredients are weighed accurately and efficiently, and provides tracking capabilities for all ingredients and batches. The scale hoppers provided in this system provide the high accuracy required to meet the desired minimum inclusion requirements and the capacity to meet expected maximum batch sizes.

Features that separate Sterling Systems & Controls auger type feeders from competitors include:

  1. Industrial bearings are used at both ends of the feeder assembly to support the auger and prevent it from making contact with the auger housing.
  2. Seals in a seal plate are located between product zone and the auger bearings.
  3. An air gap between bearing and seal plates creates a buffer zone to ensure product doesn’t enter the bearings and grease doesn’t enter the product.

The augers are multiple pitch design for accurate and repeatable weighments batch after batch. The augers are kept in suspension using shaft clamps, auger thrust load is not transferred to the drive assembly therefore increasing the drive life. Shock absorbing couplings are used to help reduce the start and stop shock on the motor and drive.

Conical rectangular scale hoppers were used rather than roll over tub scales as they cause material to become airborne with a chance that the material may not completely discharge for each batch. The conical scale hoppers are of clean design with no ledges and the corners are rolled to reduce material from hanging up so that the entire content of the scale hopper is discharged.The weight of the scale is kept to a minimum in order to increase resolution and accuracy of the scale. Butterfly discharge valves are used, rather than slide gates to ensure years of leak free operation (eliminates leak from material buildup on the backside to the gate).

Sterling Systems & Controls micro ingredient batching systems with bulk bag resupply are proven designs that will increase batch quality and production capacity.  If you have questions please request a quote or contact us at 815-625-0852 or sci@sterlingcontrols.com