Mastering Liquid Metering : Overcoming the Challenges of Precision Batching
Titan Enterprises shares key insights to help engineers and operators navigate challenges of precision batching to ensure accurate measurements and smooth process operations .
Metering batches of liquids may seem straightforward at first glance - install a flowmeter in the product line , connect it to an instrument , control the measurement with on-board software , wire in a valve , enter your required volume , press a button and the right amount of liquid is dispensed into your vessel . However , real-world applications reveal a host of complexities .
Today ’ s advanced process and liquid handling systems demand highly precise flow measurement . From adding water to food production mixers , dispensing flavourings to beer or cider at point of sale , to handling aggressive chemicals , even slight inconsistencies in system design can lead to inaccuracies , wasted product , or disrupted processes .
For batching systems , the critical factor is repeatability . To achieve this , ideally the system should maintain consistent process conditions , however , this is not always feasible . For instance , temperature fluctuations throughout the day can alter fluid viscosity and volumetric flow measurements . Similarly , a decrease in the feed liquid tank level supplying the process pump can reduce the dispensing rate , impacting the accuracy of the flow meter and the flow control valve . Therefore , as a starting point , batching system designs should aim to minimise as many variables as possible within a reasonable cost . Once this foundation is established , equipment such as flow meters , pumps , and valves can be selected
70 FDPP - www . fdpp . co . uk to effectively compensate for any parameter variations .
Titan ’ s NSF-Approved Beverage Flowmeter is designed specifically as a flow measurement solution for the drink dispensing market . With its exceptional repeatability , this low-cost device is installed around the world enabling industries to unlock higher yields , whether in beverage processing equipment or a bar tap wall in a restaurant .
Critical Considerations for Liquid Batching Systems
1 . System Repeatability :
Air pockets in the line can lead to dynamic flow situations , causing volumetric errors in delivery . Ensuring a hydraulically locked system eliminates such variability and enhances repeatability .
2 . Stable Process Conditions :
Changes in pressure , temperature , or flow rate can push flowmeters into unpredictable operational zones , affecting calibration and accuracy . Maintaining consistent conditions is vital for reliable performance .
3 . Pulsating Flow Management :
Selection of the pump type is important to avoid pulsating flow . Pulsation from certain pumps can disrupt flow rates , especially in aggressive chemical applications . Pressure regulators and pulsation dampers should be incorporated into flow systems to achieve a smooth and constant flow .
4 . Strategic Placement of Flowmeters :
Positioning the flowmeter just before the dispense valve minimises fluid inertia and improves measurement accuracy .
5 . Understanding Flowmeter Resolution :
Low-resolution meters , such as those with one pulse per litre , may lack precision in small batch applications . However , going too high in resolution is an unnecessary expense when choosing equipment . Selecting the appropriate resolution for the task is critical for reliable performance .
6 . Valve Selection and Calibration :
The type of shut-off valve used can impact delivery accuracy . Fast-acting solenoids are ideal for smaller pipelines , while larger setups benefit from solutions like multi-stage shut-off systems programming to fine-tune results .
7 . Optimising Electronic Flowmeters :
High-performance batching meters ( such as Titan ’ s ultrasonic Atrato ® flowmeter ) can predict stop signals in advance , ensuring consistent delivery even at high speeds .
By accounting for these factors during system design and commissioning , engineers can eliminate common pitfalls in liquid metering and achieve extremely good accuracy . And investing in the appropriate flow measurement technology that suits the application requirements will ensure that the batching system performs with precision and consistency .
For further information on advanced flow measurement solutions for batch processes and control , visit www . flowmeters . co . uk or email sales @ flowmeters . co . uk .