batchmaster III batch metering system


Fast, accurate measuring and dispensing of matrix components for cultured marble/onyx, solid surface and other cast polymers

The third-generation Batchmaster III provides recipe-based, automated measuring and dispensing of precise quantities of component raw materials used in cultured marble, cultured onyx, solid surface, or other cast polymer matrix. These materials include resin, fillers (calcium carbonate or ATH usually), and optionally catalyst and liquid base color pigments.

The Batchmaster III can accommodate three different metering modes – Volumetric, Weight Loss and Weight Gain. The system quickly meters (measures) precise quantities of the component materials used in one of the 20 recipes that can be stored in the system - which is accessed by a touch screen equipped control panel. An operator selects a recipe, presses a button, and all the ingredients of that recipe are measured and dispensed into a mixing pot, where a blender or vacuum mixer (solid surface) is used to produce the final blended matrix.

Use of this system will automate raw material measuring by quickly and accurately dispensing raw materials - reducing the time and reducing the potential errors from manual measuring and mixing, and reducing wastage and spillage.

Batchmaster III Control Panel

Key Features

Support for three different metering modes - The system programming supports three different metering modes - Volumetric (the most common), Weight Gain or Weight Loss. Note: optional scales are available and required for using Weight Gain or Weight Lost modes (see "Optional Metering Mode Upgrades" below).

Recipe Management - store up to 20 different cast polymer matrix formulations, and meter those with push button convenience.

Integrated Control Panel - user-friendly, convenient touch screen control panel (shown above).

Resin system:

  • Rotary gear pump for the fastest most accurate metering of resin in the industry.

  • Meter heated resin to a desired output temperature with integrated computer-controlled resin heating system, equipped with resin recirculation system to maintain heated resin at temperature when in stand-by (pause) mode.

  • If desired, additional valving can be added to the system to recirculate and heat the resin source/day tank to a second desired temperature.

Bulk Filler Management:

  • The filler metering hopper on the Batchmaster III uses a three inch core auger that accurately dispenses the desired amount filler requested.

  • The hopper has an integrated anti-bridging system to ensure accurate metering. With the addition of a weight loss scale, the filler metering system will accurately meter by weight those materials that don’t normally flow well.

  • The Batchmaster III also has the ability to operate an optional second filler hopper. This feature will allow the user to meter recipes that require different fillers.

  • Built into the metering hopper is a level sensor that will automatically activate the optional ground hopper that will keep the metering hopper filled.

  • Adding an optional ground hopper eliminates the need to frequently manually load the filler metering hopper on the Batchmaster, and provides a longer term, more convenient supply of filler from bulk bags. This also eliminates paper waste from paper bags of filler.

Optional Catalyst System:

  • The integrated catalyst system accurately meters the desired quantities of catalyst.

  • The system has a six gallon (22 liter) reservoir that allows an operator to run all day without adding catalyst.

  • The system while in stand-by mode is continually circulating and offers a consistent blend of catalyst with immediate and accurate delivery.

Optional Base Color System:

  • Precise metering of liquid base color pigments.

  • Rotary gear pumps are employed to continually circulate the pigment base while in the stand-by mode, minimizing any material settling and ensuring consistent and accurate material delivery.
  • Can operate two separate base color systems.
 

Specifications

RESIN SYSTEM

Promoted resins (or cobalt promoter system option required)
Maximum 2500 centipoise (at working temperature) promoted polyester resin, with no particulates
Approximately 32 lb (14.5 kg) per minute maximum output
2” Y-type strainer with chemical hose and quick disconnects
Integrated computer controlled resin heating system with recirculation
Cleanable heat exchanger
Control output temperature as well as recirculation temperature.
Ability to control day tank/source temperature

CONTROL SYSTEM

PLC based
Programmable batch size from 0 to 999 lb (453 kg)
Up to 20 recipe combinations (of resin, filler #1, filler #2, catalyst, base color #1 or base color #2)
Touch screen control
Start/Stop control buttons for resin, fillers, catalyst and base-color
Four pre-programmed batch sizes/recipe selections, as well as on-demand custom batch sizes
Three output modes weight gain, weight loss or volumetric
Fault system and built-in diagnostics
Dispensing in automatic sequence or manual mode
Raw material totals
Password protected recipes and data

FILLER HOPPER

Maximum output rate approximately 125 lb (453 kg) per minute
Integrated anti-bridging device
Integrated Ground Hopper control system
Weight loss/gain option available

CATALYST OPTION

Output up to 230 grams per minute
Positive displacement recirculation pump
Six gallon (22 liter) capacity

BASE COLOR OPTION

Output up to 500 grams per minute
Rotary gear pump recirculation
7 gallon (26 liter) reservoir
Liquid pigments required

ELECTRICAL SYSTEM

75 amp, 230 VAC, 3-phase 60 Hz

AIR SUPPLY

80 psi (550 kPa), 10 cfm (283 lpm)

DIMENSIONS

Frame size - 24” wide x 84” deep x 81” high (61cm wide x 214cm deep x 206cm high)
Electrical/Control box - 16” wide X 16” high x 6” deep (41cm wide x 41cm deep x 16cm high)

Order Information

Batchmaster™ III Automated Metering System (Volumetric only) - #150131
Note:  for using Weight Gain or Weight Loss metering modes, select from the Metering Mode Upgrades below:
 

Optional Metering Mode Upgrades

Weight Loss Scale Option Assembly for Batchmaster III (recommended for lightweight fillers) - includes Scale Assembly, Metering Hopper Extension and Ground Hopper Leg Extension) - #180389
Weight Gain Scale Option for Batchmaster III (2500 lb capacity, floor model) - #180390
 

Optional Accessories:

Catalyst Metering System - #30BMCA
Add Second base color - #CMBCS-1C
Base Color System with Stand - #163770
Low Level Sensor (for Ground Hopper) - #162967
Bulk Bag Support - #150160
Batchmaster Rotator - #150215
Batchmaster Catalyst Dispenser - #30BMCA
1-Base Color Unit with Stand - #163770
Micron Filter - #111095
Y-Strainer (with filter included) - #160296
Poly Pro Ball Valve (for resin) - #0832100
Inline Resin Security Valve (use with Bulk Resin system) - #162168
Quick Release Assembly (resin hook-up kit, 10' of hose with fittings) - #150600
Resin Transfer Hose (per foot) - #111571
Stand for Resin Tote Bin - #111474T-R
Resin Tote Bin - #111474-R
 

Other Related Accessories:

Ground Hopper for Batchmaster (45 degree auger incline) - #150445B
Bulk Bag Suspender Frame (hang bulk sacks over your Ground Hopper for added filler capacity - #150160
Bulk Bag Gantry - 6-Leg, 20' - #08312081
Bulk Bag Roller Conveyor, per 10' section - #0831216
Shuttle Base (Wheels), 12' long (used with weight loss unit) - #1100455H
Shuttle Cart (for 1100455H), Each - #163027
350 lb Blender Shuttle Cart - #150114*
350 lb Blender Shuttle Cart with Track to Scale - #150115**
350 lb Blender Shuttle Cart for 2nd Cart on 150115 - #162247
* Forward only shuttle to be used with one blender only (Weight Gain)
** Shuttle system designed to move sideways can use two carts (350 lb Blenders)(Weight Gain)
 

Documentation:

Display Panel Screen Protectors

screenprotectorsmall

Keep your machine's Control Panel screen clean and readable!

Available for Autocaster Ultra, Autocaster Economizer and Batchmaster II and III models!

  • Extend the life of your touchscreen and keep it looking like new!
  • Long lasting protection against dust, scratches and gouges.
  • Abrasion and chemical resistant to protect the LCD screen. Now clean matrix off the screen protector with acetone!
  • Anti-glare film provides added screen contrast and brilliant colors.
  • Installs easily, removes cleanly without leaving residue.
  • Filters out 99% of UV light from reaching your screen or reflecting to your eyes.
  • Reduce expensive service calls or touch screen replacements due to screen damage

Order Information

  • For Autocaster Ultra/PC systems from 2015 and newer Autocaster Ultra (fits TP1500 screen) - Order No. 166117  - USD $24.00
  • For Autocaster Ultra/PC systems pre-2015 (2014 and earlier) (fits MP370/377 screen) - Order No. 166120 - USD $15.50
  • For Batchmaster III and pre-2012 Autocaster Economizer systems (fits HG2F screens) - Order No. 166119 - USD $12.46
  • For 2013+ Autocaster Economizer systems (fits HG3F screens) - Order No. 166118 - USD $15.54
  • For Batchmaster II systems (fits TP170A screen) - Order No. 180376 - USD $12.46