Sterling Systems & Controls' BatchControl Pro semi-automatic batching system helps manufacturers improve ingredient accuracy, lot traceability and batch documentation. The operator-guided station validates ingredients, enforces weight tolerances and records production data in a Structured Query Language (SQL) database.

The system guides operators through programmed recipes using on-screen prompts. It verifies ingredient and lot information before allowing the process to advance. Real-time tolerance monitoring helps prevent incorrect ingredient additions and out-of-spec batches.

BatchControl Pro also automates calculations for target weights, bag counts and tare weights. Optional barcode and radio-frequency identification (RFID) scanning supports ingredient identification and lot confirmation.

The system stores batch records for historical analysis, audit reporting and production oversight. Available reports include batch summaries, ingredient usage, ingredient deviations and inventory audits. Manufacturers can also print batch reports using a ticket or network printer.

Sterling designed BatchControl Pro for applications involving dry and liquid ingredients. Target industries include food processing, animal feed, pet food, pharmaceutical, nutraceutical and chemical manufacturing.

The system can also support future production changes. Its SQL-based architecture provides an upgrade path to automated minor and micro ingredient systems.

Sterling will be offering hands-on demonstrations of BatchControl Pro at Pack Expo International 2026 October 18-21 at McCormick Place in Chicago.