Pros and Cons of Batching System Types

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By: Carlton Scale

Batching is the process of turning raw materials into finished goods. When building batching systems by weight, most engineers will design batching processes as either a full manual batching, semi-manual batching, or automated batching system. The chart below details pros and cons of each system:

 Batching System

PROS

CONS

Manual 
  • Low upfront cost
  • More manual control of batching by operators
  • Limited “moving parts” in system
  • Higher likelihood of bad batching
  • Not as efficient as semi-manual or automatic processes
  • Limited to no native PLC integration

Semi-manual
  • Lower upfront cost of most fully automated solutions
  • PLC Integration via batch controllers
  • More efficient than manual batching
  • depending on design, Easy for operators to use
  • Not as efficient as automated solutions, due to operator input
  • May require more equipment and integration due to batch controller user prompting
  • Higher likelihood of bad batches compared to fully automated solutions

Automatic
  • Easy PLC integration
  • Eliminates bad batches due to batching/mixing errors
  • Most efficient operation
  • High ROI
  • Often single push-button operations.
  •  Higher upfront cost

Inconsistent results during a batching process can lead to defects, lost batches, and unmet standards. Bad batches are one of the top reasons for decreases in customer satisfaction with customers. The right batching system will give way to easy processes and higher process transparency while improving the bottom line in your production.

 

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