The Client manufactures precision precast refractory parts and assemblies, specializing in metal transportation, filtration, and casting applications. A batch of casting material is made up of a wide range of particle sizes, shapes, and flowability and must be accurately weighed into a mixing bowl. The bowl is then transported to the mixer where the liquid ingredients are added while mixing. This mix is then poured into molds.
It is crucial that the batch maintains an even particle distribution as well as repeatable batch weight accuracy. They have been manually weighing several hundred-pound batches with an operator and shovel, which is a safety concern for the plant. ISL performed an onsite demonstration taking random catch samples at the discharge, which were positively analyzed in their lab for segregation. The demonstration also proved how easily and safely an operator could work with an ISL system and its ability to control the flow rate for batching.
ISL proposed two Gain-In-Weight IBC batching stations, each equipped with a bulk and trim sensor, dust extraction manifold, floor scale with ramp, and batch controller. The operator simply pushes the mixing bowl onto the floor scale, enters the desired batch weight then presses, “Start Batch.” Any dust is evacuated to their central dust collector system while the material is discharging. Once the batch setpoint is met, the operator safely rolls the mixing bowl off of the scale and over to the mixer.
This system satisfied all of their criteria by:
1. Delivering +/- 0.1 lb on various batch sizes up to 500lb
2. Maintaining product uniformity
3. Offering a safe and operator friendly workstation