Frequently Asked Questions

Weighing and feeding is the process of measuring the rate of bulk material running through a system before dispensing it into a process. Automated systems, like weigh feeders and belt scales, help control the flow of bulk material, accurately measure it, and feed it into numerous processes such as blending, packaging, and mixing.

The most common methods of weighing are gravimetric, loss-in-weight, and gain-in-weight. Gravimetric weighing measures material by its actual weight in real time using load cells and scales for high precision. Loss-in-weight measures the weight decrease over time when material is fed from a hopper. Gain-in-weight measures the material being added to a hopper until a target weigh is reached.

A belt scale measures material weight on a conveyor with no ability to control material flow rate. A weigh feeder measures weight on a belt with the ability to precisely control the material flow rate by automatically adjusting the belt speed. A belt scale is best used in processes where a reading of totalized weight and high flow rate are prioritized. A weigh feeder is better suited to providing a consistent flow of material at a desired set point for accurate feeding or blending of material.

A good belt scale consists of high accuracy and repeatability along with durability. Accurate measurement of material flow is an essential function of a belt scale. The ability to withstand harsh conditions while requiring minimal maintenance is also crucial for a reliable belt scale.

Weighing and feeding systems usually consist of a load cell, a transport mechanism (such as a belt, screw, or vibratory tray), and an integrator/controller.

A load cell measures the weight of material as it passes, while a speed sensor measures the belt speed. A controller receives both signals and calculates the real-time feed rate. For a conveyor belt scale, the totalized weight in a given timeframe is reported (i.e TPH). For a weigh feeder, the system compares the live feed rate to the desired feed rate setpoint and adjusts the speed of feeder belt as needed.

Weighing and feeding is essential to an efficient operation and can provide numerous benefits when optimized for the application. Precise measuring and dosing reduces material waste, helps maintain product consistency, and enables accurate ingredient mixing/blending. Maintaining proper weighing and feeding can also result in decreased costs and higher quality products.

Upgrading old equipment can significantly improve accuracy, increase production, boost efficiency, reduce downtime and costs, while ensuring adaptability and versatility for future use. Merrick offers a host of upgrade options for equipment in various industries that are custom-designed and built to help optimize your current operations.

Automation is key to efficient weighing and feeding. As more processes are automated correctly, efficiency increases due to reduced manual labor and downtime. For example, in a blending process, a Merrick Orbital Loss-In-Weight feeder can significantly boost production due to its ability to accurately weigh and discharge multiple materials into a recipe simultaneously.

Although the fundamental principle of weighing and feeding is the same for most applications, equipment must be designed and built differently for each industry to accommodate different needs. For example, a facility processing food might require a weigh feeder with sanitary features to prevent contamination. While a weigh feeder for a cement plant will need rugged construction to withstand much harsher conditions.

In food and pet food, contamination and general uncleanliness can lead to major issues. To prevent these potential problems, Merrick has developed weighing and feeding options equipped with a host of sanitary features that still provide reliable accuracy. A Merrick weigh feeder like the Model 970 is built using stainless steel, a belt that can be easily removed for cleaning and maintenance, and many other sanitary features.

In heavy industries, it is important for equipment to be able to withstand harsh conditions during daily operation. Merrick has developed a line of weigh feeders that are specifically designed for these conditions. Merrick’s Model 450 can handle heavy usage in rough environments and produce accurate results when weighing bulk materials due to its rugged construction and unique design.

Yes, custom designed and manufactured weighing and feeding equipment does provide extra benefits. When a weigh feeder is designed for a specific application, it can operate to its maximum capabilities and thus boost production. A weigh feeder being used for a process it’s not designed for can not only lead to suboptimal results but may even hinder plant operation. Merrick works closely with each customer to custom design solutions that fit their needs and requirements.

Water and wastewater treatment is crucial in protecting public health, preventing the spread of certain diseases, and preserving ecosystems. It ensures safe drinking water by filtering out harmful bacteria and chemicals, preventing waterborne diseases. Proper treatment of water and wastewater protects the environment by preventing the release of pollutants and stopping contamination of natural water bodies and ground water.

A hydrated lime slurry system can be more effective when designed to maximize performance while simplifying operation and maintenance. Merrick’s High Density Lime Slurry (HDLS) systems represent an advanced approach, using less hydrated lime, make-up water, and power than traditional systems while reducing downtime and eliminating the need for a recirculation loop. HDLS systems maintain a stable suspension that prevents pipe scaling and settling under normal operating conditions, resulting in lower maintenance requirements.

In the event of an operating issue, The Merrick support team is available 24/7 for emergency hotline assistance and are stationed throughout various hubs around the USA for a quick response and prompt in-person service.

It is critical for plant personnel to be familiar with the system for regular operation as well as in case of emergencies. The Merrick support team offers in-person educational classes that can help inform team members how to properly and safely operate Merrick equipment to maximize efficiency at the plant.

Material handling is critical for operation efficiency, product quality, and inventory optimization. When material handling is done correctly, a plant can operate efficiently, thus boosting production and improving delivery time. As a result of this, a higher quality product is likely to be manufactured at a more efficient pace. Finally, when material is discharged at the correct dose for accurate recipes, inventory space at the plant is utilized more effectively and available space within the facility is maximized.