For scenarios with multiple material types and large production scales, the selection of automated batching equipment should focus on the four core principles: high compatibility, high stability, high intelligence, and high capacity. The following eight aspects should be prioritized to meet the needs of large-scale continuous production:
1.Multi-Material Compatibility and Adaptability
It needs to cover the precise handling of materials with different physical properties (granules, powders, liquids, viscous materials, etc.), focusing on the equipment's multi-channel design and customized adaptive components:
Hopper System: Equipped with multi-specification partitioned hoppers (classified by material properties; e.g., powder hoppers with arch-breaking devices, viscous material hoppers with wall-scraping mechanisms). The number of hoppers is flexibly configured according to material types, supporting simultaneous storage of 10-50 material types.
Conveying and Metering Units: Select dedicated equipment for different materials—such as belt batching scales for granules, loss-in-weight feeders for powders, and mass flowmeters + metering pumps for liquids—to ensure stable feeding and no cross-contamination for each material.
Anti-Pollution Design: Adopt independent conveying pipelines + quick cleaning interfaces, supporting CIP online cleaning to meet clean production requirements in industries like food and pharmaceuticals.
2.High Capacity and Continuous Operation Stability
Large-scale production has strict requirements for the equipment's continuous operation capability and capacity redundancy to avoid full-line shutdown due to single-point failures:
Capacity Design: The rated capacity of the equipment should reserve 30%-50% redundancy to adapt to capacity fluctuations during peak production; adopt a parallel batching architecture, with multiple batching units working simultaneously to improve overall batching efficiency.
Reliability Configuration: Core components (sensors, motors, valves) use high-end industrial-grade brands with fatigue resistance and wear resistance; key stations are equipped with redundant backup systems (e.g., dual weighing sensors, backup conveying channels) to enable quick switching in case of failures.
Wear Resistance and Protection: Components in contact with materials are made of wear-resistant ceramics or 316L stainless steel to extend equipment service life; dust-proof, moisture-proof, and explosion-proof devices are configured to adapt to different production environments.
3.High Precision and Formula Management Intelligence
In multi-material proportioning scenarios, batching precision directly determines product quality, requiring intelligent systems for precise control:
Metering Precision: The metering precision of key materials (e.g., additives, catalysts) should reach ±0.1%-±0.5%, and that of ordinary materials should be controlled within ±1%; equipped with a dynamic calibration system to support online automatic calibration and eliminate the impact of environmental factors (e.g., temperature, humidity) on precision.
Formula Management: Equipped with an advanced PLC+MES system, supporting storage of over 1,000 formulas, which can be automatically called according to production orders; supports formula encryption and version management to prevent formula leakage or misoperation.
Traceability Function: Integrate barcode/RFID identification systems to record data such as batching time, dosage, and equipment status for each batch of materials, realizing full-process traceability of production.
4.Automation and Intelligent Integration Capability
Adapt to the full-process linkage needs of large-scale production lines, realizing seamless connection between the batching link and upstream/downstream processes:
System Integration: Support docking with enterprise management systems such as ERP, WMS, and MES, automatically receiving production orders, issuing batching tasks, and feeding back production data to realize closed-loop management of planning-batching-production.
Unmanned Operation: Configure automatic feeding systems (e.g., AGV, manipulators) and automatic waste recycling devices to reduce manual intervention; support remote monitoring and operation to realize 7×24 unattended production.
5.Efficient Energy Consumption Control and Cost Optimization
Large-scale production needs to balance capacity and energy consumption to reduce long-term operating costs:
Energy-Saving Design: Adopt frequency conversion speed-regulating motors + energy-saving valves to dynamically adjust energy consumption according to actual capacity; configure energy recovery systems to recycle waste heat and residual pressure during equipment operation.
Consumables Management: Monitor the service life of vulnerable parts (e.g., conveyor belts, seals) through intelligent systems to realize preventive maintenance and reduce unplanned shutdown losses; use standardized components for consumables to lower replacement costs.
6.Flexible Production and Expansion Capability
Adapt to the needs of multi-variety, multi-batch production, while reserving space for future capacity upgrades:
Flexible Configuration: The equipment adopts modular design, supporting quick switching of batching formulas to adapt to product structure adjustments; hoppers and metering units can be increased or decreased as needed to meet the batching needs of new materials.
Expansion Interfaces: Reserve production line expansion interfaces; in the future, capacity can be doubled by adding batching units and upgrading control systems without replacing the entire machine.
7.Safety Compliance and Environmental Protection Requirements
Large-scale production must strictly comply with industry safety and environmental protection standards to avoid compliance risks:
Safety Protection: Equipped with safety light curtains, emergency stop interlocks, overload protection and other devices, complying with international safety standards such as ISO 13849 and CE; central dust removal systems are configured for dust materials, and explosion-proof electrical components are used in explosion-proof environments.
Environmental Protection Compliance: Support waste resource utilization (e.g., recycling and reprocessing of unqualified batches); noise, dust, and wastewater emissions must meet national or local environmental protection standards to avoid environmental penalties.
8.Full-Lifecycle Services and Supply Chain Support
The long-term stable operation of large-scale equipment relies on perfect services and supply chain support:
Supplier Qualifications: Prioritize suppliers with large-scale project implementation experience (e.g., Sihyde Qingdao Automation Equipment Co., Ltd.), which can provide one-stop services from scheme design, customized R&D, installation and commissioning to operation and maintenance.
After-Sales Guarantee: Establish a local after-sales team + remote operation and maintenance center, providing quick repair services with 2-hour response and 24-hour on-site arrival; sufficient spare parts inventory is available to ensure timely replacement of key components.
Technical Training: Provide customers with full-process training on operation, maintenance, and programming, cultivating a professional operation and maintenance team to improve the independent management capability of equipment.
9.Sihyde Automated Batching sistem
Summary of Sihyde Qingdao Adaptation Scheme
Sihyde Qingdao Automation Equipment Co., Ltd. provides customized intelligent batching systems for multi-material and large-scale production scenarios. Relying on multi-channel compatible design, industrial-grade stable configuration, and MES system integration capability, it realizes precise proportioning of multi-materials and efficient continuous production. At the same time, the company helps enterprises reduce costs and increase efficiency, and calmly respond to product iteration and capacity upgrade needs with a perfect local service system and modular expansion scheme.
