How To Use A Batch Controller

What Is A Batch Controller and What Is It Used For? In industries where time is equivalent to money, businesses are constantly in the hunt for ways to maximize operations. Thanks to a huge advancement in technology, machines play a massive role in ensuring that production is running swiftly and businesses are using every minute wisely. Through these machinery and equipment, things are working at a different level and pace. Perhaps one of the successful and extremely reliable results of technology that greatly affects huge  industries are machinery built for batching and filling up large quantities of products. One example are Batch Controllers; equipment that are designed to measure the amount of liquid or gas and the number of items processed through a line or tube. 

Unlike items made in solid materials where counting each of them individually is not an issue, it is a bit more complicated when it comes to getting the quantity of liquids and gases. Batch Controllers are specifically created to perform this task- through tubes where gases and liquids flow (for example, gases flow per minute) and velocity is used to measure their volume. Batch Controllers also control pumps and valves to read the flow of gas and liquids and fill the required volume into a container.

Batch Controllers designed to do repetitive jobs by batches with less time consumed, eliminating the need for a large workforce. Perfect for both small-scale and large-scale manufacturing, they require no special hardware equipment and can even work offline. You can also monitor the time consumed per job takes and manage huge workloads in a short amount of time.

Batch Controller - Gedge System

How Do I Use A Batch Controller?

When you operate a batch controller, it is important to know that this equipment can only be operated by trained and authorized operators inside the facility who are made aware of the safety instructions, rules and precautionary measures involving the operation. 


Before starting the installation process, make sure that the measuring system is accurately wired up according to the wiring diagrams. Danger from electrical shock or any other accidental contact is no longer guaranteed as soon as the cover of the housing is removed or the cabinet panel has been opened, which is why only the authorized operators inside the facility are the ones allowed to open the housing. Since the batch controller is powered by a microprocessor that is sensitive to interference, pay attention to the wires you connect.

These wires should not interfere with the connection of pumps and motors which might throw off the signal. The wires should be positioned away from a clean power source and should steer clear of input power lines. If you ever encounter any electrical noise, the first thing to do is to shield your cable with a protective unit and then hook it to the DC ground terminal. Make sure that the power is only connected after other connections are complete. In case you are unsure, it is best to consult and check the diagram for proper wiring instructions and make sure that everything is connected properly.

When you purchase a batch controller, brackets are usually included in the package to hold the batch controller firmly in place. Now, as soon as the wirings are inspected and checked, it is important to position the batch controller securely with a gasket that has a tight and reliable seal. Once you are sure that the body of the batch controller is fitted through the gaskets, insert the handle and secure the stews at the back of the brackets.

Now, once the batch controller is installed properly, you can begin using the batch controller. The reading must be reset to zero so that you can program your batch controller to give you the results that you require for your operation. Once the start button is pressed, your batch controller will automatically count with the right signals. If you press the preset button, it will present when the account reaches the program number. Know that the reset button can be activated at any time while your batch controller is functioning.

You might notice an array of buttons (one button to put in a code to unlock the panel, one button for entering, one button to preset programming things at a certain time, and one button to display program choices) To know the rate and total, you may use the view button. To present functions and features such as the pre-warn delay, the batch total and grand total, you may use the start button. With the batch controller, you can also manage the rate of work and time spent by familiarizing yourself with the other input commands you might wanna use during operation. You can also connect your batch controller to a printer to instantly get printed results. Know that it is advisable and useful to connect your batch controller to a computer to transmit data, receive data and have it printed afterwards. 

How Do I Maintain A Batch Controller?

It is always a good decision to get services from the same manufacturer that supplied your batch controller. Carrying out regular calibration services and quality checks will check the accuracy of the batch controller, determine the traceability of the measurement and repair the device if it is out of calibration. This usually involves a report provided by the calibration expert, showing the error in measurements of the measuring device before and after the calibration. If you own a batch controller, look out for the following:

  • Power button not lighting up
  • Intermittent errors 
  • Incorrect count
  • An FFFFFF is showing on the display

Calibration allows you to get reliable and accurate numbers for safety purposes. This is especially important when you are measuring electric currents, or mixing explosive chemicals wherein even the smallest changes to your numbers can rapidly put your staff in danger. Accurate measuring, brought by regular calibration  is perhaps the most effective way of averting costly repairs or even claims for damages. Problems can be proactively resolved during normal maintenance times rather than waiting for failures to occur, which can eventually cause production shutdowns. If you’re looking for more reasons to require calibration services, think about the regulations you need to obey and the quality systems you need to follow. Aside from your company’s quality system, you need to include Environmental responsibility and various regulations and standards.

To make sure that you purchase a batch controller of the highest quality, and that it is properly handled, the application engineers from Gedge Systems will be pleased to give you advice on the best possible solution.


27 Rhur Street,

Dandenong South VIC 3175 

Australian Contact (03) 9791 8944

International Contact +61 3 9791 8944