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Automated weighing and batching system with pneumatic conveying for bulk material handling by Knitcons Solutions

Introduction

Automated weighing and batching system with pneumatic conveying for bulk material handling by Knitcons Solutions

Knitcons Solutions offers advanced Weighing and Batching Systems designed for precise, repeatable, and dust-free handling of bulk materials. Our systems help industries automate material measurement, improve product consistency, and reduce manual handling.

By integrating high-accuracy load cell weighing with dense phase pneumatic conveying system, dilute phase pneumatic conveying system, Knitcons ensures clean, reliable, and efficient material transfer across the production process.

What is a Weighing and Batching System?

A Weighing and Batching System is an automated solution that accurately measures predefined quantities of bulk materials and transfers them to the next stage of processing.

When combined with pneumatic conveying, materials are transported through closed pipelines using air, ensuring:

  • Zero dust emission
  • No contamination
  • Consistent batch accuracy

How the Knitcons Weighing & Batching System Works

Step-by-Step Operation

  • 1. Material Loading
    Raw material is fed from storage silos or bag dump stations.
  • 2. Accurate Weighing
    Material enters a weigh hopper mounted on precision load cells.
  • 3. Batch Control
    Once the target batch weight is achieved, the inlet valve closes automatically.
  • 4. Material Transfer
    The batch is conveyed pneumatically or by gravity to mixers, reactors, blenders, or packing machines.
  • 5. Automatic Reset
    The system resets and prepares for the next batch with complete repeatability.

Key System Components

  • Bag Dump Station / Storage Silo
  • Weigh Hopper with Load Cells
  • Pneumatic Conveying Line (Pressure / Vacuum)
  • Control & Diverter Valves
  • PLC Control Panel with HMI
  • Blower or Vacuum Pump
  • Powder Transfer System

All systems are custom engineered by Knitcons Solutions based on process requirements.

Types of Weighing & Batching Systems

1. Gain-in-Weight Batching System

  • Measures material added into the hopper
  • Best for batch processes and multi-ingredient recipes

2. Loss-in-Weight Batching System

  • Measures material discharged from the hopper
  • Ideal for continuous and high-precision dosing

3. Single Component Batching

  • Accurate dosing of a single raw material

4. Multi-Component Batching

  • Automated recipe-based batching of multiple materials

Advantages of Knitcons Weighing & Batching Systems

  • High weighing accuracy (±0.1% to ±0.5%)
  • Fully automated and PLC controlled
  • Dust-free and hygienic material transfer
  • Reduced material wastage and spillage
  • Consistent product quality
  • Easy integration with existing systems
  • Low maintenance and long operational life
  • Reduced manpower and operating costs
  • Improved batch consistency
  • Better traceability and process control
  • Faster production cycles
  • Scalable system design for future expansion
  • Food & Beverage – Flour, sugar, milk powder, spices
  • Pharmaceuticals – APIs, excipients
  • Chemicals – Powders and additives
  • Plastics & Polymers – Granules, masterbatches
  • Cement & Minerals – Fly ash, additives
  • Paints & Pigments – Specialty powders

Why Choose Knitcons Solutions?

  • Customized system engineering
  • Proven expertise in bulk material handling
  • Food-grade & GMP-compliant designs available
  • Robust construction and reliable performance
  • End-to-end support: design to commissioning

Trusted Automated Weighing and Batching System Manufacturer in India

GMP Certification
Make In India
ISO 9001 compliance

Conclusion

The Weighing and Batching System by Knitcons Solutions delivers precision, automation, and efficiency for modern industries. With advanced control and pneumatic conveying integration, our systems ensure consistent production, reduced losses, and long-term operational reliability.

FAQs

An automated weighing and batching system is an industrial solution that accurately measures predefined quantities of bulk materials such as powders, granules, or solids and transfers them automatically to the next stage of production. These systems use load cells, PLC controls, and automation software to ensure precise, repeatable, and error-free batching.

The system feeds raw material from storage silos or bag dump stations into a weigh hopper mounted on load cells. Once the target weight is achieved, valves close automatically, and the batch is discharged via pneumatic conveying or powder transfer systems to mixers, blenders, reactors, or packing machines. The system then resets for the next batch.

  • Gain-in-weight batching systems measure material added into a hopper and are ideal for batch processes and multi-ingredient recipes.
  • Loss-in-weight batching systems measure material discharged from a hopper and are best suited for continuous and high-precision dosing applications.

Yes. When integrated with pneumatic conveying and powder transfer systems, the weighing and batching system operates in a fully enclosed, dust-free environment, preventing material loss, contamination, and workplace pollution.

Automated weighing and batching systems are widely used in:
  • Food & Beverage (flour, sugar, spices, milk powder)
  • Pharmaceuticals (APIs, excipients)
  • Chemicals & specialty powders
  • Cement & minerals (fly ash, additives)
  • Plastics & polymers (granules, masterbatches)
  • Paints & pigments

Knitcons Solutions’ systems deliver high weighing accuracy ranging from ±0.1% to ±0.5%, depending on material characteristics and process design. This ensures consistent batch quality and reduced material wastage.

Yes. Multi-component weighing and batching systems from Knitcons are designed for recipe-based batching, allowing multiple raw materials to be weighed, controlled, and discharged automatically through a PLC-based control system.

Yes. All Knitcons weighing and batching systems are fully PLC controlled with HMI, enabling automated operation, batch tracking, data logging, and easy integration with existing plant automation systems.

Absolutely. Knitcons Solutions offers custom-engineered weighing and batching systems based on material type, batch size, accuracy requirements, plant layout, and industry standards such as food-grade or GMP compliance.

Knitcons Solutions is a trusted weighing batching system manufacturer with proven expertise in bulk material handling, pneumatic conveying, and industrial automation. We offers robust designs, high reliability, customized engineering, and end-to-end support from design to commissioning.