ControlPro v3.4
This article assumes you’re already familiar with the process of sub-batching. If you’ve never worked with sub-batching before, I recommend you read our article, “Introduction to Batching and Sub-Batching” before proceeding. This article covers automatic sub-batching. If you need assistance with manual sub-batching, or sub-batching with equipment, refer to our other articles covering those topics.
Automatic sub-batching is mostly used in dry systems. Dry systems use a mixer to combine ingredients before dispensing. It is common for the customer to request a delivery that is larger than the mixer can process. We use sub-batching to fix this problem.
In the following examples, we are using a mixer with a capacity of 8,000 lbs. and will be processing tickets with a requested amount of 10,000 lbs. The screenshot below shows the system settings with 8,000 lb. mixer capacity, and 20,000 lb. maximum batch size.
I loaded a ticket into the system with the requested amount of 10,000 lbs. Notice in the total batch pounds field, it’s 8,000 lbs. That’s because of the primary mixer capacity limiting the batch size. You can increase that amount up to the maximum batch size. The system will never let you deliver a batch larger than the maximum batch size.
To make sure the customer gets their full order, we need to sub-batch this delivery. There are two ways to do this. The first is to use default automatic sub-batching. The second method is automatic sub-batching with equalize. In this first example, we'll show the default method.
To achieve this, load the ticket into the system and go to the batch details tab. Under there, check the box to use sub-batching. Then click automatic. Under the total batch pounds field, change it from 8,000 lbs to 10,000 lbs. When ready, click process.
When processing, you’ll see it mix and process the first batch. The first batch is 8,000 lbs., two materials with 4,000 lbs. each. It also lists it as Sub-Batch 1 of 2.
Immediately after the first sub-batch is completed, it will start processing the following batch. The next batch is only the remaining amount of 2,000 lbs. The sub-batch is labelled 2 of 2.
So, when you choose automatic sub-batching with the default settings, it will deliver maximum amount until the last sub-batch, where the remaining amount is delivered.
The other automatic sub-batch method is called equalize. This equalizes the amount of each sub-batch. In the previous example, we received two sub-batches, one of 8,000 lbs., and the other was 2,000 lbs. If we use the equalize setting, it will deliver two sub-batches of 5,000 lbs. each for a total of 10,000 lbs.
In the screenshot below, we are processing a ticket with 10,000 lbs. of material. When choosing equalize and setting the total batch pounds to 10,000, it creates two sub-batches. Sub-batch 1 of 2 is 5,000 lbs.
When that sub-batch completes, the system automatically starts processing the second batch. In this screenshot, you can see it say sub-batch 2 of 2 which is 5,000 lbs.
Those are the two methods used for automatic sub-batching. Please refer to our other articles for help with manual sub-batching and sub-batching with equipment.