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 manual sub-batching. If you need assistance with automatic sub-batching, or sub-batching with equipment, refer to our other articles covering those topics.
Manual sub-batching gives you the flexibility to control each step of the sub-batching process. With automatic sub-batching, the system automatically runs each sub-batch one after the other. In manual sub-batching, you must manually set and complete each sub-batch before moving to the next one. This creates more steps but gives you the flexibility to control each step of the process.
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. To do manual sub-batching, follow these steps.
After the ticket is loaded, go to the batch details tab. Check the box to enable sub-batching, then click the manual setting. Under the total batch pounds section, fill in 10,000 lbs. so we deliver the entire order. At the bottom right, you’ll see the sub-batch field activates itself in manual mode. Here you manually fill in how much you want to run in the batch. For testing purposes, I’ll run 6,000 lbs. in the first batch, then 4,000 lbs. in the second batch for a total of 10,000 lbs.
Here, I changed the sub-batch to 6,000 lbs. The requested amount was updated after I adjusted the sub-batch. When ready, click process.
Once the sub-batch is delivered, you see the delivered amounts were updated, and the remaining batch amount has been calculated for you. Also, the system status will change to “waiting”. ControlPro is waiting for you to manually start the next sub-batch. When you’re ready, click the process button again to start the next sub-batch.
Once the second sub-batch is delivered, the system goes into waiting status again. This time, since all material has been delivered to the customer, we need to manually complete the ticket. When you click the complete button, the ticket will close, and the batch details screen will clear itself. Notice how the sub-batch field is still active with an amount of zero pounds. You can over-deliver and add more sub-batches if that’s what you want.
If you need to deliver a ticket and omit one or more of the materials, you can achieve that with manual sub-batching. Add the ticket to the system, highlight the ticket, then go to the Batch tab. Check the box to ignore blend ratio. Then check the box to use sub-batching and place it in manual mode. Once all three are set, you can double click the field under the sub-batch requested column. Once the cursor appears, you can edit the amount. Set to zero if you want to omit the material, or any other amount if you want to adjust it.
Manual sub-batching mode gives you the ability to control each step of the process. You set the sub-batch sizes, and step through each sub-batch, one at a time. If you want a more streamlined sub-batching process, check out our article on automatic sub-batching.