All You Need to Know about Batch Controllers

Batch Controllers | Flowmetrics

When working with flowmeters it is important that the amount of liquid or gas that flows through is controlled. Without a batch controller, there is a risk that too much or too little of the material that you are using will enter the flowmeter system.

What Are Batch Controllers?

Batch controllers are a piece of equipment that measures the number of items that are processed or the amount of liquid or gas that flows through a line. Solid items are easy to calculate as individual items can be counted, but it is a little more complicated when it comes to liquids and gases.

Liquids and gases flow through tubes and the volume is measured by the velocity, for example, the amount of gas that passes per minute. In terms of a flowmeter, this part of the operation will show the volumes, and the batch controller will show the amount of gas or liquid that has flowed through the tube.

Why Use a Batch Controller?

In industries where there is a high level of production, it is not viable for somebody to constantly measure how much of a product is entering the flowmeter system. For one, your workforce would need to be huge and, furthermore, you may not be able to measure as accurately as you would like to.

Once a batch controller has been given relevant instruction, it can get on with the job at hand with little interaction. Batch controllers are particularly useful when carrying out repetitive work, such as measuring the correct amount of ingredients for food recipes or medicine.

Modern digital batch controllers have a high success rate and very rarely do they malfunction, unlike the old style of timer controllers.

How to Mount a Batch Controller

It is essential that the batch controller is mounted securely with a gasket that has a reliable seal. Brackets are usually included when you purchase from the manufacturers so that it can be held firmly in place.

Once the body is fitted through the gaskets and the handle has been inserted, the stews can be secured at the back of the brackets.

Batch Controllers in Manufacturing

When researching what batch controller to purchase for your operation, you will need to opt for one that gives total readings. Various manufacturers use different hardware and software, with many designing specific batch controllers to suit certain industries.

Upon receiving and installing your batch controller, the reading will be set to zero so that you can program it to give you the results that you require for your operation. Once you have entered the correct credential, you can choose to look at readings at intervals or once the process is fully completed. Readings can be taken manually by looking at the digital display or some controllers have a handy print out feature.

If you think that you have made an error and you can see that the controller is not working the way it should, there is an option to ‘stop’ or ‘reset’ it. To do this, you will need to enter a code that you have set up when first installing the controller.

The display will show you the rate that the material is passing through the line and the total volume or number that has been part of the overall process. It is important to note that you can only use scales up to 5 digits on most batch controllers.

It may take a bit of time to get used to using a batch controller so you should be prepared for a small margin of error until you are fully familiar with the different commands that you can give to it. It is recommended that you choose a manufacturer that will offer full training or an in-depth manual on how to fully operate your new piece of equipment.

Summary of the Benefits of a Batch Controller

  • Repetitive jobs can be done quickly in batches without needing a large workforce
  • No special hardware equipment is required
  • Batch controls are great for large and small-scale manufacturing
  • Batch controls can work offline leading to less stress on the processor
  • A batch control can detect how long a job takes and will form a queue of jobs
  • You can set your batch controller to work at set times
  • Batch controls can manage large workloads in a short space of time

Choosing the Right Manufacturer

Installing a batch controller is reasonably straightforward, as explained above, but you may still want to ask an experienced technician to install one for you. A batch controller is used to ensure that you get the maximum output from your operations, by using the correct amount of materials for your product with little waste. With this in mind, a sound understanding of the different settings and outputs will give your business the edge.

Investing in a reliable controller that will last for a long time, will make sure that the installation will run smoothly and that you have a piece of equipment with a reliable warranty. When researching companies to purchase your controller from, you should ask questions about what maintenance can be offered and if there would be support if any problems were to occur.

Batch Control Maintenance

If you choose to purchase your controller from a firm that cannot carry out regular maintenance, it is essential that you get to know your equipment inside out. Carrying out regular quality checks will prevent your controller from failing completely and you should look out for the following issues:

Power button not lighting up—this is likely to be an issue with the wiring.

Intermittent errors (skipping or jumping)—interference could be the problem which means you will need to look at the power supply.

Incorrect count—you will need to look at the scale factors, transmitting device and the wiring.

FFFFFF on the display—the controller may be trying to count a number that is too large or small, so your scaling factors will need to be amended.

4 thoughts on “All You Need to Know about Batch Controllers

    1. Hi Sania, thank you for reaching out to us at Flowmetrics. What “items” are you looking to process with the help of a batch controller?

    1. Hello Babucarr. Calibration is usually done in a lab environment. The flowmeter to be tested is connected to the test bench and tested against a “known” flow. There is more information in several of our blog articles located at

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