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FABS - Formulation and Batching Supervisory System FABS - Formulation and Batching Supervisory System FABS - Formulation and Batching Supervisory System

"Monitor what you make, record what you made"
batching system

  • Fast - Accurate Batching

      • - Prompts operator through schedule of formulas to be batched
      - Enforces ingredient tolerances
      - Monitors operator productivity
      - Optional clean-out batches minimize cross-contamination

  • Historical Batch Traceability

      • - What ingredients and lots went into a batch?
      - Who batched it?
      - When was it batched?
      - What were the target and actual amounts?

  • Track Ingredient Usage

      • - Receives ingredients into inventory
      - Depletes inventory as ingredients used
      - Tracks vendor lot numbers from start to finish
      - View batches for specified lots, formulas, operators, and dates

  • Designed for the Environment

      • - Ruggedized equipment on the plant floor
      - PC stays in the office
      - Off-the-shelf standard components
      - Modular, easy to maintain design

    FABS software

    Working in conjunction with the superb Weigh-Tronix WI-130/WPI-135/1310 Weight Display, The FABS Formulation and Batching Supervisory System controls and monitors the manual fill of ingredients into a scale mounted container.

    Mobile scale station cart equipped with a Weigh-Tronix 1310, bench scale, and battery with a DC/AC inverter

    The FABS System consists of two software components. The first program resides in the WI-130/WPI-135/1310 Display on the factory floor and controls the manual filling of multiple ingredients, by weight, into a container on the scale. The second program resides in a remote PC and monitors the filling operation and collects data from the filling process. The PC program then provides complete record keeping and reporting for management control of the filling process.

    The FABS System can accommodate up to two separate filling lines with up to four active filling stations/scales per line. Transactions for all active stations and lines are constantly monitored and recorded at the remote, PC location. The PC operator can watch the results of each filling operation and can modify and download new formulas to each station separately, as the process requires.


    Main menu of the WI-130 FABS batching station

    At the filling station, the scale weight display prompts the operator through each stage of the filling process, displaying each formula and the associated ingredients for the formula.

    The WI-130/WPI-135/1310 monitors the filling of each ingredient and prevents the operator from under filling or overfilling the ingredient target weight.

    WI-130 FABS batching station showing the ingredient to be batched and it's target amount

    The WI-130/WPI-135/1310 then records the results of each batch and transmits the completed batch information back to the remote PC system.

    WI-130 FABS batching station showing progress of the ingredient being batched

    The unique display of the weight indicator provides the scale operator with detailed and exact information to make the filling process accurate and efficient.



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    Seed Blending System

    Six (6) individual hoppers, equipped with a variable speed vibratory feeder, are mounted on load cells. The operator enters a blend/formula number into the weight indicator/controller, which controls output proportionately. Each feeder dispenses onto a takeaway conveyor which eventually feeds into a "finished mix" hopper with bagger.

    Operation

    Controller Setup:
    1) Supervisor enters the various blend numbers and their percentage per hopper requirements
    2) There could be formulas where all 6 hoppers are not used, as in the case of simple blends that are only a three or four variety mix

    Operator Sequence:
    1) Once all the supply hoppers have been filled, a blend number is entered into the 1310 using the keypad
    2) Upon verification of correct blend number the 1310 prompts to "PRESS START BUTTON"
    3) Operator depresses start button, 1310 energizes the appropriate feeders with an output level signal and begins to monitor weight loss/time long enough to establish the appropriate output level to send for each hopper so as to get the correct blend
    4) There is an automatic/manual switch on the control panel for times when there is a need to empty individual supply hopper and/or other requirements


    FABS Software and Hardware Specifications

     

    Software Specifications

    PC software

    Supports Windows 2000/XP (2000 recommended)

    Scale Support

    Weigh-Tronix Solution Series, supports multiple scale stations and multiple production lines

    Scale User Interface

    Dot graphic display, 5”W x 1.33”H, 240 x 64 dots cold cathode.  Simultaneously displays 0.6” high readings of Weight, Lot number, Recipe, Ingredient, Target, etc.

    Scale Operating
    System

    Event driven functionality triggered by actions such as scanning of Recipe or Lot number, pressing a function key, or pressing a Weight Accept button

    Network Support

    Windows Network ready.  Data can be stored anywhere on company wide network. Data is retrieved from the scale stations TCP/IP sockets via wired Ethernet or industry standard Wi-Fi IEEE 802.11a/b components.

    Compatibility and
    Data Storage

    CSV, Fixed Record Length, SQL Server, DB2, Oracle, Sybase, Access, dBase, Paradox, FoxPro, Excel, and other ODBC compliant databases

    Security

    Five level user password system. Tracks and records all user actions in system log files

    Barcode
    Specification

    Code 39, Extended Code 39, Codabar, Code 128, Code 11, Code 93, EAN-13, EAN-14, UCC/EAN-128, I 2 of 5, UPC, PDF, and other standard formats

    Production Scheduling

    Allows supervisor to schedule up to fourteen different recipes in a “Production Schedule”.

    Inventory

    Tracks inventory from raw materials received to finished goods shipped

    Reports

    Comprehensive standard report system.  User guided Report and Graph Wizard.  Ad-hoc Query system for user definable custom reports.

    Online Help

    Comprehensive online help with lookup index

    Remote Support

    Remote support provided via PC Anywhere, Carbon Copy, WinVNC, or VPN (Virtual Private Network) with annual support contract.

     


    Hardware Specifications

    Computer

    Pentium II processor or greater
       -1 GB available hard disk space
       -256 MB RAM
       -PC Anywhere 10.0 with modem or Internet connection
       -Uninterruptible Power Source (UPS)
       -Network Connectivity

       -RS232 serial port (for Serial version)

    Computer Location

    Local Server (in office, not on mixing floor)

    Scale

    Weigh-Tronix Solution Series Instruments with Bench or Deck Scales

    Communication

    Ethernet, RF, 802.11a/b, or RS-232

    Network

    Ethernet and Industry standard Wi-Fi IEEE 802.11a/b components

    Scanner

    Supports most RS-232 decoded output scanners

    Printer

    Supports most RS-232 based thermal label printers.  Recommend Zebra XI series or Datamax I class

    Support

    90 days included, annual contracts available



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