Preferred supplier for ingredient processing and production lines

I. Core Technology: Multi-dimensional Sensing and Precise Control

The core of an automated ingredient mixing system lies in its real-time data acquisition and dynamic adjustment capabilities. The system monitors parameters such as material weight, flow rate, and temperature in real time through a high-precision sensor network (such as weighing modules, flow meters, and temperature sensors), with errors controlled within 0.1%. For example, in milk powder production, the addition of trace nutrients requires accuracy down to the milligram level. Weighing sensors use dynamic compensation algorithms to eliminate mechanical vibration interference, ensuring that the mixing ratio error for each batch does not exceed ±0.5%.

The PLC, as the "brain" of the control system, is responsible for processing sensor data and executing logical operations. Taking the Siemens S7-1500 series PLC as an example, it can simultaneously control 20 mixing lines, dynamically adjusting the feeder speed through PID control algorithms to achieve segmented control of "coarse addition - fine addition": the coarse addition stage quickly fills to 90% of the target value, and the fine addition stage approaches the final value at a low speed to avoid overshoot. In addition, the DCS (Distributed Control System) ensures seamless connection between different stages (such as feeding, mixing, and packaging) through multi-node collaboration, improving single-line production efficiency by more than 50% compared to manual operation.

II. System Architecture: Layered Control and Flexible Collaboration

The automated ingredient mixing system adopts a "three-layer architecture" design:

Equipment layer: Includes hardware equipment such as raw material silos, feeders (screw/belt type), mixers, and packaging machines, equipped with actuators such as frequency converters and pneumatic valves, supporting 0-10V/4-20mA analog control.

Control layer: The PLC or industrial PC acts as the central controller, running customized control programs (such as logic developed on the CODESYS platform) to achieve functions such as recipe management, sequence control, and fault diagnosis. For example, a chemical company uses a PLC-linked MES system to automatically record the supplier, batch number, and operation log of each batch of raw materials, meeting GMP audit requirements.

Monitoring Layer: HMI software (such as WinCC, Intouch) provides a human-machine interface, supporting recipe editing, production monitoring, data traceability, and remote maintenance. Operators can start the production line with one click via the touchscreen, and the system automatically generates production reports (such as raw material consumption, energy consumption, and equipment OEE), and sends out abnormal alarms (such as weighing deviations, empty silos, and motor overheating).

III. Functional Advantages: Cost Reduction, Efficiency Improvement, and Quality Control

The value of the automated batching system is reflected in four dimensions:

Increased Accuracy: Eliminating human error, batching accuracy is consistently within ±0.5%-1.0%, significantly improving product consistency. For example, after a feed mill introduced the system, it could complete the production of 20 different formulas in a single day, and the customer complaint rate decreased by 70%.

Flexible Manufacturing: The system supports rapid changeovers, storing hundreds of process parameters in the recipe library, allowing product switching in just 3 minutes. A pharmaceutical company used this function to share tablet and capsule production lines, increasing equipment utilization by 40%.

Safety and Compliance: Robotic arms replace manual handling of hazardous chemicals, reducing occupational exposure risks; the system automatically records operation logs, meeting FDA, ISO, and other certification requirements.

Cost Optimization: By reducing raw material waste (error rate reduced by 3%), lowering energy consumption (equipment idle time reduced by 50%), and extending equipment life (load balancing control), overall costs are reduced by 20%-30%.

IV. Typical Scenarios: Cross-Industry Application Practices

Food Industry: In a mango juice production line, the system dynamically adjusts the formula based on the sugar and acidity of the raw materials to ensure consistent taste for each batch; the CIP (Clean-in-Place) program automatically controls the cleaning agent ratio, shortening changeover time.

Chemical Industry: A paint company uses an explosion-proof batching system to achieve precise mixing of titanium dioxide and solvents in a flammable and explosive environment, and controls the emission concentration below 10mg/m³ through a dust collection device. Pharmaceutical Industry: The system integrates visual inspection modules to monitor tablet weight and appearance defects in real time, automatically rejecting substandard products; access control prevents formula leaks, ensuring intellectual property security.