BIRD SEED MANUFACTURING: Seed and Grains Batch Blending
A manufacturer of bird seed needed to accurately blend various seeds and grains together in order to produce the final bird seed blends that would be sent to packaging as a final product. The customer was batch blending the various ingredients and then storing the blended material in a bin for final packaging. The customer was having quality control issues with the various blends because the adjustments to flow rate and the batching of the various materials was all done manually. Some of the blend issues that the customer was experiencing were so bad that entire blends were deemed unusable and were discarded. The customer wanted to be able to control the flow rate of the individual materials as they emptied from their respective bins onto a mixing conveyor. They also wanted the batches of each product to be precise, so that the final blends were consistent and repeatable. The flow rate and batch size of the individual ingredients could change depending on the bird seed blend that they were making. Since each type of bird seed ingredient was stored in a separate silo, the customer wanted to be able to call forth a specific bird seed recipe and have the correct amount of each ingredient be dispensed from the silos, through a feed device and ultimately, onto a mixing conveyor that would blend the separate ingredients. The material would then be stored until needed for a production run of that bird seed blend. The feeder also needed to maintain its accuracy across the entire flow range without calibration or accuracy drift, regardless of the batch size.
EASTERN INSTRUMENTS SOLUTION
The customer installed a mix of CentriFeeder ICV units and CentriFeeder MCV units, one under each silo. The units selected for installation were chosen based on the desired flow rates for each of the materials. The units were a mix of CentriFeeder ICV-06 and MCV-06 feeders with integrated control valves. The feeders each had a local color, touchscreen HMI that displayed flow rate and total. The set-point for both flow rate and total could be entered via the local display, or sent down to the feeder from a PLC.
Once the CentriFeeders were installed and the calibration was completed by our onsite service technician, the feeders performed well within the desired measurement accuracy of +/-0.25% over the full range of the feeder and had a batching accuracy of within +/-0.50%. The accurate and consistent batching of the various CentriFeeders ensured that the customer could depend on the quality and consistency of the bird seed mixes. This tight control over the batch blending operation allowed for major savings in materials as well as a more consistently manufactured product for their customers.
MATERIAL TEST REPORTS: Roofing Shingles and Supplies
A variety of CentriFlow Meters and CentriFeeders have been used in the production of shingles, in order to measure the various components of the shingles as the shingles are being manufactured. They have even been installed in locations measuring the load-out as these components are loaded into trucks and rail cars.