Collaboration and Ratio Control
Mixing and blending of materials is a frequent, important process in the food industry and other industries, often with the final mixture required to contain a critical specific ratio of the components. The approach most often adopted is to control the flow rate of each component into the mixing tank to realize the specified ratio, a pre-defined flow rate ratio (i.e. 5:1)
In our experience, The Batch Brothers have noticed this approach can lead to problems, in that inevitable variations in the established flowrates will result in a ratio of the components in the final blend other than that specified. By only implementing the flow rate ratios the system may reach the end of the blending process and end up with material that was not blended in.
The Batch Brother’s solution is to monitor the weight of each component remaining and provide a homogeneous blend based on the remaining weight ratios, this way the system is constantly correcting for ratio errors based on materials remaining and not just instantaneous flow rate. The flowrates Ratio setpoints are constantly calculated to maintain a ratio based on the ratio of materials remaining. This approach is particularly beneficial if the individual materials are not homogeneous, perhaps containing particles clumped together which may lead to instant flow errors.
The Batch Brothers also advocate a collaborative work culture so that information is available to all stakeholders. This collaboration implies that opportunities for improvement identified by any employees or provider should be expressed to the team and evaluated.
Batching Across America,
-The Batch Brothers