Ferro Alloy Feeding & Batching Solution
Precision, Efficiency, and Automation in Alloy Batching
What is the FAFA System?
The FAFA System (Ferro Alloy Feeding & Batching System) by ProQuip is an advanced solution designed to streamline the automated feeding and batching of ferro alloys in steel plants and alloy manufacturing units. Engineered for precision and efficiency, the system ensures consistent and accurate material handling, minimising manual effort and reducing process variability.
Equipped with key components like vibro-feeders, belt conveyors, sector gates, motorised rotary chutes, and pocket elevators, the FAFA System provides seamless flow and exact batching of ferro alloys into melting furnaces. Its modular and customizable design makes it ideal for a wide range of industrial applications.
Whether you're upgrading an existing process or planning a new setup, the ProQuip FAFA System helps improve productivity, reduce material wastage, and support automation goals—delivering a reliable, low-maintenance solution tailored for modern steel manufacturing operations.
Key Components of the FAFA System
Each unit plays a critical role in accurate ferro alloy batching and delivery.
⚙️ Automation-Driven Precision for FAFA
Pro-Quip’s Ferro Alloy Feeding & Batching System (FAFA) delivers unmatched precision in dosing and feeding critical alloying materials. With advanced automation, it ensures exact measurement, clean handling, and seamless coordination with your furnace — all with minimal human input.
Key Automation Highlights:
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⚖️ Automated Alloy Batching – Load-cell accuracy with recipe-based dosing for consistent composition.
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🔁 Sequenced Feeding Logic – PLC-controlled feeding by time, weight, and priority.
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🖥 Centralised HMI Control – Live monitoring, recipe management, feed adjustments, and batch reports.
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📊 SCADA Integration – Plant-wide visibility, data logging, and performance insights.
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📶 Flow Verification Sensors – Automated detection of bridging, blockages, or underfeed.
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🚨 Safety Protocols – Interlocks, overfeed protection, and real-time system feedback.
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With FAFA, Pro-Quip transforms alloy feeding into a fully integrated, safe, and reliable alloy management solution.
How the FAFA System Works
A step-by-step overview of the automated ferro alloy feeding and batching process.
1️⃣ Material Loading into Hopper
Ferro alloys are loaded into hoppers that act as primary storage units, providing a consistent buffer for uninterrupted batching.
2️⃣ Controlled Feeding via Vibro-Feeder
Electromechanical vibro-feeders discharge material at preset frequencies, allowing for accurate volume control and precise batching.
3️⃣ Sector Gate Discharge & Batch Formation
The alloy flows through timed sector gates, ensuring each batch is precisely calculated for downstream processing.
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4️⃣ Material Transfer through Belt Conveyor
The batched material moves horizontally on a belt conveyor, minimising spillage or segregation during transfer.
5️⃣ Distribution via Rotary Chute or Elevator
Final batched material is either directed to the furnace through a rotary chute or elevated via a bucket/pocket elevator to storage bins or processing lines.
Why Choose the FAFA System by ProQuip
The FAFA System isn’t just a batching solution—it’s a strategic investment for any steel or alloy manufacturing unit looking to streamline operations, improve precision, and reduce labor dependency. Designed and developed by ProQuip, a trusted name in process automation, the system delivers unmatched performance, reliability, and customization.
Key Benefits:
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High Precision Batching
Ensures accurate feeding of ferro alloys into furnaces, reducing material wastage and enhancing process consistency. -
Automated Operation
Reduces manual intervention through programmable logic and mechanized flow control, saving labor costs and human error. -
Modular & Scalable Design
The FAFA System can be tailored to your plant’s layout and expanded as your production grows. -
Rugged & Low-Maintenance Build
Built with high-grade components that offer long life cycles and minimal maintenance downtime. -
Smooth Material Handling
Integrated components like rotary chutes and vibro-feeders ensure non-disruptive, spill-free flow across all stages. -
Improved Safety & Efficiency
Automation leads to fewer on-ground hazards and more streamlined, controlled operations.
With over a decade of experience in industrial process automation, ProQuip offers more than just products—we provide complete, custom-engineered solutions. From consultation to design, manufacturing, and support, our focus is on delivering quality systems that align with your operational needs.
When you choose ProQuip, you're choosing innovation, expertise, and reliability—backed by proven performance across steel and alloy industries.