Food Productivity Guide

Increase Productivity with

High Performance Weighing & Measuring
Food Productivity Guide

2 METTLER TOLEDO © 12/2016 - Food Regulatory Guide

 Table of Contents
Table of Contents

Chapter 1 Traceability for Standard Compliance and Process Improvement 6

Chapfer 2 Improved Production Yield Through Process Oriented Recipe Management 12

Chapfer 3 Advanced Batch Control for Increased Process Transparency 18

Chapter 4 Inventory Control – Tank & Silo Weighing 24

Chapter 5 Ergonomic Manual Portioning – Solutions to Increase Efficiency 30

36
Chapter 6 7 Considerations for Cleaning Production Equipment

Chapter 7 Integrating Process Data from Industrial Weighing 42

Chapter 8 Greater Process Reliability with Intelligent Sensors 48

Chapter 9 Package Quality Control – Net Content Control 52

Chapter 10 In-line Checkweighing – Aspects of a Key Technology 58

Chapter 11 Vision Inspection – Driving Quality and Process Security 64

Chapter 12 Foreign Body Detection – Metal 70

Chapter 13 Foreign Body Detection – X-ray Inspection 76

Chapter 14 Reliable Vehicle Weighing Helps Protect Profits 82

Chapter 15 Moisture Analyzer Routine Performance Testing 88

Chapter 16 Efficient Quality Management in a Regulated Environment 94

METTLER TOLEDO © 12/2016 - Food Regulatory Guide 3

 Prepare to Optimize Production
Food Productivity Guide

and Increase Profits

Improving production efficiency is vital to successful business operations. Food man-

ufacturers must continually optimize production parameters to enhance profit margins
and react swiftly to changing consumer demands. This guide offers 16 solutions for
continuous process control and optimization to improve your operation.

Food manufacturers are always under pressure to It serves as a reference for those involved in process
produce more in less time. Consequently, weighing design and equipment selection.
and measuring solutions must be designed to op-
timize performance, enhance efficiency and improve This guide helps you to optimize:
product quality. • Throughput for manual and automated processes
• Formulation and batching and filling processes
The goal of this productivity guide is to offer you rele- • Product giveaway and overfill reduction
vant information to optimize your production efficiency. • In-line process control
The second edition of the guide has been compre- • Product safety with foreign-body detection
hensively updated, offering 16 chapters with ideas for • Tracking and tracing processes
process improvements and cost optimization. • Process risk management

4 METTLER TOLEDO © 12/2016 - Food Regulatory Guide

 Select Your Focus Topics
Regardless of your role in Food production, we have solutions and expertise that
Topics

can help you. Choose a role in the blue header and then look below for the relevant
topics and pages for you.

Material Production Production Inventory Packaging Shipping Quality Mainte-

Receiving (manual) (automated) Control Distribution Assurance nance IT

Traceability /
Product Identification • • • • • • • 6

Formulation /
Recipe Weighing • • • • • 12

Batching /
Material Transfer • • 18

Inventory Control /
Tank & Silo Weighing • • • • • 24

• • •
Manual Portioning /
Over / Under 30
Checkweighing

Process Weighing
Data Integration • • • • • • • 42

Process Sensors
• • • • 48

• • • •
Quality Data Man-
agement / Net Content 52
Control / SQC

In-line
Checkweighing • • • • 58

Vision Inspection
• • • • 64

Foreign Body Detection

Metal Detection • • • • 70

Foreign Body Detection

X-ray Inspection • • • • 76

Hygienically Designed
Equipment • • • • 36

Vehicle Weighing
• • 82

• • • • • • •
Management of
Quality in a Regulated 94
Environment

Moisture
Determination • • • • 88

METTLER TOLEDO © 12/2016 - Food Regulatory Guide 5

 Traceability for Standard Compliance
Traceability
and Process Improvement

Reoccurring incidents such as e-coli in spinach and dioxin in pork emphasize the rising
importance of efficient traceability. Tracking & tracing food, feed, and food-producing
animals through production and distribution stages is proving vital to consumer safety
and company reputations.

Food Safety regulations such as EU178/2002 or US

Bioterrorism Act, as well as retail-driven standards, re-
quire food suppliers to assure traceability on a one-up/
one-down principle but do not dictate methods. Some
companies comply using paper-based systems; others
may require full networked computer and bar code
systems to effectively meet requirements.

This paper focuses on in-plant traceability and dis-

cusses how good traceability not only helps a manu-
facturer comply with legal and regulatory require-
ments; it also shows how the right systems and
equipment can contribute to production efficiency
through better stock management and minimized
waste.

Contents
1 The Importance of Traceability
2 Designing a Traceability System
3 Verifying Product Safety
and Quality Attribute Checks
4 Documentation
5 Traceability Testing
6 Traceability Technologies
7 Summary
8 Additional Resources

6
 1 The Importance of Traceability

Traceability is a legal requirement for food, feed and What is traceability?

related products. In addition, it is a basic element in Traceability is defined as:
Traceability

safety and quality management schemes such as the ‘Ability to … follow raw materials and components
GFSI accepted standards (BRC, IFS, SQF, and intended to be, or expected to be, incorporated into
FSSC 22000) or in national industry and product spe- a product, through all stages of receipt, production,
cific regulations (e.g. EU beef labeling regulations). processing and distribution.’

Traceability requirements are linked to legislative de- Traceability can also ensure that product safety and
mands that any product placed on the market shall be quality attributes have been checked (country of origin,
fit for purpose and not injurious to health. As a risk species of animal, whether all components are
management tool, traceability allows businesses and quality-checked and released for production or that
authorities to withdraw products identified as un- products are free of foreign bodies).
safe. It also:

• Minimizes costs incurred by making recall more

effective
• Allows targeted action to prevent recurrence
• Assists in problem diagnosis, passing on liability
where relevant
• Promotes customer confidence and brand protection
• Optimizes production efficiency and quality control
(stock control, material usage, and origin/character-
istics of products).

MES / ERP System

Formulation Software

Quality Data Management Software

Raw Primary Secondary Shipping Retail,

Processing Processing Packaging Stock Hotels,
Material
Catering
Material Batching Commisioning Distribution &
Receiving & Order Preparation Shipping
Labelling Labelling

QC Formulation
Laboratory Room

Material Analysis Ingredients & Reci-

Batch release pe Control ID Points

Figure 1: Software solutions for ID Points, Formulation Recipe Weighing and Quality Data Management

METTLER TOLEDO © 11/2016 - Traceability 7

 2 Designing a Traceability System
Legislation generally requires a ‘one up’/‘one down’ Consider where batches merge/diverge and traceability
approach to traceability. Integration of internal and may be reduced or lost; establish what information is
Traceability

external systems improves efficiency. Therefore, it is going to be recorded and how.

worth considering systems operated by raw mate-
rial or component suppliers as well as customers to The system should include documentation of interme-
understand a company’s interaction within the supply diate/semi-processed materials, those that are part-
chain. used, rework, and any rejected materials or those ‘on
hold’ pending investigation.
General principles
Some general principles to consider when designing
or challenging an existing traceability system include Data Integration (e.g. SAP)
making sure that it:
• Covers all stages of production, processing and dis-
tribution
• Identifies raw materials suppliers
• Identifies which components have been used in
which product
• Identifies supplied customers
• Identifies which products and intermediates have
been disposed of (verification of destruction may be IND890
required) terminal
• Ensures products supplied to customers are ade-
quately labeled or identified to facilitate traceability
• Provides details to authorities on-demand in a timely Barcode
manner. scanner

An ideal system fits into a company’s normal work

practice and enables quick and easy collection of rele-
vant information.
Label printer

Risk assessment
Relevant variables such as the nature of products and
Printer
raw materials must be considered through adequate
risk assessment. Design will depend on on elements Bench or
such as: Floor scale
• Number/nature of raw materials and components
• Criticality and risk of components used
• Batch/lot sizes and uniformity
• Production processes Figure 2: Weighing Station with METTLER TOLEDO Indicator IND890
• Number of component combinations & lot splits as ID Point

8 METTLER TOLEDO © 11/2016 - Traceability

 Batches terial must be checked against the amount used in the
Unique identity codes such as: delivery date, production resulting finished products, taking process waste and
or run time, batch size, and expiry date should be used. rework into account. Thus:
This may consist of an internal system for assigning a A+B+C = processing = X, Y, Z
(raw materials) (yields/waste/rework) (finished products)
sequential number, or use the supplier’s batch code or
Traceability

GTIN (Global Trade Identification Number).

It is unlikely that the mass balance check will account
for all materials to 100% accuracy; however, any dis-
Codes should include enough detail to ensure trace-
crepancies should be justified (such as ingredient de-
ability back to the production batch.
hydration). A company must demonstrate that it under-
stands the variance to ensure traceability system
Labeling
effectiveness. Mass balance is a key measure that can
Consider labeling suitability. Traceability is often con-
also highlight areas for improvement.
fused if ‘old’ labels are not removed from containers.
When implementing a system, investigate alternative
systems of marking, such as:
Timing
The traceability system must allow actions such as
• Permanent marking pens
isolation of an unsafe batch or recall from a depot to
• Labels aimed at minimizing contamination risk (for
be taken within an appropriate time frame. This time
example, metal-detectable labels, RFID)
frame will relate to product characteristics such as
• Reusable, visually-distinct tags.
shelf life, production process/supply chain complexity,
and consumer risk.
Quantity check
In order to account for all materials, quantity details
should be included. The amount of incoming raw ma-

3 Verifying Product Safety and Quality Attribute Checks

A traceability system can be used to confirm that safe- An growing number of consumer products must be
ty and quality checks have been performed and suffi- supported by an electronic file containing documenta-
cient records have been retained for verification. This tion that demonstrates the product meets safety stan-
is particularly significant when investigating customer dards. This file becomes part of the traceability sys-
complaints and legal compliance. Any test results, tem. It is good practice to use technical files even
such as microbiological testing, must also link back to when it is not a specific legal requirement.
original batches.

4 Documentation

Meaningful documentation provides evidence of pro- Additionally, if traceability is used for confirming that
duction history such as: safety/quality checks have been performed, then the
• Incoming goods records and raw material quality following documentation would also be required:
checks • HACCP or hazard analysis documentation
• Intermediate component records or mix recipes • Process records for manufacturing the finished
• Warehousing and storage records product
• Delivery orders to the final customer • Operator instructions for the recording of batch
• Records of any subcontracted work codes for all raw materials, work in progress
and finished products
• Personnel training records

METTLER TOLEDO © 11/2016 - Traceability 9

 Legislation dictates traceability record retention time- need to be kept at least six months. Otherwise,
frames related to product characteristics. For example, general rules dictate a 5-year retention minimum.
foods with a shelf life of less than three months would
Traceability

5 Traceability Testing

The company should determine the method and fre- low system improvements. The company must prove
quency for traceability system checks depending on how quickly information can be collated and corrective
production process complexity and product criticality. action – such as quarantine – can be taken.
Regular testing will demonstrate effectiveness and al-

6 Traceability Technologies

Regulations and certifications require traceability, but expensive.Intelligent weighing terminals connected to
none are prescriptive. A system may be paper- or barcode printers and scanners can clearly mark and
computer based. The best system fits into the compa- identify raw materials received, semi-finished and final
ny’s normal working practice and enables easy infor- products. For areas with multiple formulation process-
mation access. Weighing scales are often important es such as vitamin premixes or spice kitchen, PC-
material identification points in a traceability system based recipe weighing can provide seamless docu-
(Figure 1). mentation of how much of what component was
weighed when, where and by whom. Benefits include
Paper-based systems material flow transparency, better stock management
A paper system may be cost-effective for processes and human error reduction. Improved production
with limited number of materials/components and little follow-through may be guaranteed for some industry
lot combination/split situations. But documentation segments.
practice and form design will need to be reviewed to
reduce human error risk. Integrated systems
Integrated solutions that include scales, scanners and
Barcode labeling printers from goods-in to shipment provide the highest
Bar code systems can be more accurate where large level of traceability. All data can be linked and pro-
amounts of data need to be tracked. Internationally cessed in real-time, providing clear identification of
recognized GS1 Standards can ensure integration of raw materials/intermediate components and ware-
information throughout the supply chain matching in- housing/storage records. Genealogy trees allow imme-
formation flow with physical flow. Because of its ability diate upstream tracing and downstream tracking
to provide globally unique identification of trade items, of potentially faulty components and batches.
assets, logistic units, parties and locations, the GS1 General efficiency improvement through functions
System is particularly well suited to be used for trace- such as yield analysis, line performance comparison
ability purposes. RFID systems provide efficient, inter- and stock optimization help improve productivity.
active data management as well but are typically more

10 METTLER TOLEDO © 11/2016 - Traceability

 7 Summary

Recent worldwide recall episodes have heightened the Integrated technology can help eliminate manual re-
profile of traceability. Implementing state-of-the-art cord-keeping, save time and eliminate error potential.
Traceability

traceability offers: It also improves quality control and supports data inte-
• The ability to perform fast, precise product recalls gration into existing MES or ERP systems. Ultimately,
• Minimized number and scope/impact of recalls a well-designed traceability system will provide easier
• Enhanced consumer protection and confidence fulfillment of legislative principles and a wealth of data
• Improved brand building & protection that can help with internal process improvement.
• Increased production efficiency and quality control

8 Additional Resources

• Directive 2001/95/EC on General Product Safety contains an extract from the BRC Global Standard
(2001) – This European directive requires compa- Best Practice Guideline Traceability and remains the
nies to have traceability systems to effect recall of copyright of the BRC. If you wish to purchase a copy
dangerous or illegal products from the market. please visit the BRC Bookshop
http://eur-lex.europa.eu/LexUriServ/LexUriServ.do www.brcbookshop.com
?uri=OJ:L:2002:011:0004:0017:en:PDF
• RASFF – The Rapid Alert System for Food and Feed
• Regulation (EC) No 178/2002 of the European (RASFF) enables the rapid exchange of information
Parliament and of the Council of 28 January 2002 whenever a risk to food or feed safety is identified.
This European regulation lays down the general http://ec.europa.eu/food/safety_en
principles and requirements of food law, establish-
ing the European Food Safety Authority and proce- • METTLER TOLEDO Formulation / Recipe Weighing
dures in matters of food safety. Solution
www.food.gov.uk/multimedia/ www.mt.com/formulation
pdfs/1782002ecregulation.pdf
• METTLER TOLEDO Quality Data Management
• GS1 – Global organisation for design of systems in- Solution
cluding traceability standards. www.mt.com/freeweigh
www.gs1.org/productssolutions/traceability/gts/
• METTLER TOLEDO Traceability Solutions
• BRC Global Standards – This chapter “Traceability www.mt.com/traceability
for Standard Compliance and Process Improvement”

Mettler-Toledo GmbH
Industrial Division
www.mt.com/ind-food-guides
CH-8606 Nänikon, Switzerland For more information
Tel. + 41 44 944 22 11

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364112 / Marcom Industrial
11
 Improved Production Yield through
Formulation
Process Oriented Recipe Management

Food manufacturing companies are under increased pressure to improve plant productivity,
product quality and consumer safety. For all three, ingredient traceability and process
tracking play central roles.

International standards designed to ensure product

safety (EC 178/2002, US Bioterrorism Act, FDA, GMP,
BRC, IFS, ISO 22000) are cropping up. A prerequisite
to the traceability required is documentation of all rele-
vant formulation and weighing process activities.

A computer-guided and networked, rather than paper-

based, production system provides easily accessible
production data. The resulting documentation and
analysis can improve quality, reduce waste and protect
both consumers and brand reputation, providing signif-
icant bottom-line improvement.

This paper will address the benefits of investing in such

a system as well as considerations that help ensure the
system enhances manufacturing processes.
Contents
1 Increasing Regulatory Pressure
Requires Traceability
2 Traceable Weighing/Formulation
Is Computer-Based
3 System Components/Configuration
4 Integrated Traceability
5 Summary
6 Additional Resources

12
 1 Increasing Regulatory Pressure Requires Traceability

From bird flu to bioterrorism threats, modern reality customer events may require investigation into pro-
has forced both governments and food processors duction steps. If defective batches appear, the root
Formulation

to impose new rules for food and allied product man- cause of the problem must be identified and measures
ufacturing. taken to ensure future product quality and safety.
The IFS (International Food Standard) – for example –
requires producers to guarantee traceability of goods Essentially, food producers must document all pro-
flow, as stated in IFS Version 5, paragraph 4.16.1: cesses – without gaps. This includes recipe develop-
Similar requirements are stipulated in BRC (British ment, quality lab, production planning, monitoring,
Retail Consortium) Issue 4, paragraph 2.13 and ISO dispensing and packaging / distribution. A computer-
22000, paragraph 7.9. ized and intelligently networked formulation / weighing
Aside from regulations, unpredictable supply-chain or system is key.

A traceability system shall be in place which enables the identification of product lots and their relation
to batches in direct contact with food, packaging intended or expected to be in direct contact with food.

The traceability system shall incorporate all relevant processing and distribution records.

2 True Traceable Formulation/ Weighing Is Computer-Based

Truly gapless traceability requires that all involved par- uct shipment. To be effective, manufacturers must en-
ties feed recipe – relevant data – ingredients, struc- sure systems provide relevant data quickly. Some
tures, work instructions, batch and production order governments request access even within few hours.
information – into a centralized system. A computer-
based system’s advantages over a paper-based sys- For example, in a recall, a manufacturer must identify:
tem include data consistency, speed of data analysis • Who delivered the spices used in batch XY of meat
and improved recall management. pie Z?
• What quantity was used?
An electronic system can also document processes, • Who released the recipe?
generate weighing and manufacturing reports, and
print labels to identify goods-in-process. This brings If end-product taste deviates from recipe expectations:
users one important step closer to compliance with EU • What area of processing needs to be adjusted?
178 / 2002; BRC; and Controls Used for Manufactur-
ing, Processing, Packing, or Holding Dietary Supple- Most critically:
ments for FDA 21 CFR Part 111 CGMP Regulations. • How quickly can a manufacturer’s current documen-
This type of system is also vital for transparent manu- tation process answer these questions?
facturing processes and providing a proper decision
base for streamlining processes. In an effective and fully networked system, this infor-
mation is immediately available when the system of-
End-to-end documentation fers features such as:
Tracking and tracing demands documentation of all
production actions from goods receiving to end-prod-

METTLER TOLEDO © 11/2016 - Formulation 13

 Recipe Database Customer Order
ORDER
10,000 pouches
Production
10’000
Swiss pouches
poucches
Mountain
Swiss
Herb Mountain
Mou
untain
Candies
Herbs Candies
100g Cand
dies
100g
Delivery date:
Delivery date:
xx.xx.xxxx
Recipe xx.xx.xxxx
Recipe
Recipe 10,000 Swiss
Recipe
Swiss Mountain Recipe
Mountain Herbs
100g
Raw Material
Herbs Recipe Ingredient #1 Preparation
Ingredient #1 Swiss Apple Ingredient #2
Ingredient #3
Upscaled
Ingredient #2 Taste
Ingredient #3 Ingredient #1 Ingredient #4 Recipe
Formulation

Ingredient #4 RecipeIngredient #2 Ingredient #5

Ingredient #5 Swiss Ingredient
Valley
#3 Ingredient #6
Ingredient #6 Fresh Ingredient #4
Ingredient #1
Ingredient #5
Ingredient #2
Ingredient #6
Ingredient #3
Ingredient #4
Ingredient #5
Ingredient #6

Weighing & Mixing

Production Report

Traceability Report
Traceability Report

Final Product

Clearly identified materials via labeling / barcoding. can offer a configurable interface between the solu-
At each stage a label indicating material and status is tions and an ERP system such as SAP.
affixed. Corresponding entries are made in the data-
base. Benefit in terms of ROI
Online monitoring. Monitoring functions offer informa- Virtually any company blending different materials in a
tion about exceptional factory situations. well-defined recipe can benefit from a computer based
Industry-standard networking. System components formulation system to streamline procedures. More ex-
communicate with a centralized database via Ethernet pensive or higher risk materials will produce the fast-
LAN. Clients such as dispensing stations and control est return on investment; however, nearly any proces-
devices such as balances, scales and other peripher- sor should be able to prove ROI on an appropriately
als exchange production data with the server. Win- scaled system in 12 months or less through:
dows-compliant applications use standard resources • Reduced consumer risk
such as network printers for reporting. • Enhanced regulatory compliance
Expandability and connectivity. System expansions • Less product waste
are possible without disturbing other components un- • Lower disposal / rework / recycling costs
less software is updated. A dedicated ERP Gateway all leading to substantial bottom-line enhancements.

3 System Components/Configuration

A standardized configurable system that has been • Orders

tuned to manage critical weighing process parameters • Preparation batches
has many advantages over client-specific systems • Warehouse status
with custom programming. • Containers
Standard interfaces allow a high degree of customiza- • Operators
tion while offering expert system maintenance and • Consumption data
support over the life of equipment and software. The • Exceptions
initial investment better maintains its value and can • Production activities
secure optimal production performance well into the • Password activities
future. • User connections
• Database activity log
Master data management • Weighing / calibration
In a networked system, a master station allows overall • Audit trail
data management and maintenance. This can include • Electronic and hardcopy reporting on the above
tracking of:
• Materials Reliability and security are critical. While processes
• Instructions can be controlled at individual process weigh stations,
• Recipes all process data is gathered at the master station.

14 METTLER TOLEDO © 11/2016 - Formulation

Formulation

User-friendly screens simplify weighing and minimize potential operator errors

Specialized weigh stations Seamless data exchange

For required formulation activities, the following weigh with ERP/MES systems
stations are available: As noted previously, ERP interfaces permit integration
• Dispensing – batch components are pre-weighed of an appropriately configured and effectively net-
and ready for execution worked weighing system with many ERP and MES
• Production – components are verified before mixing systems. Seamless data exchange avoids redundant
according to recipe sequence data maintenance:
• Dispensing & production – combines both actions, • ERP system data becomes available in the
used primarily at smaller companies where pre- weighing process.
weighing is performed in the production area • Production data is sent back without manual
intervention.
Screens must be designed for optimum readability for
fast information recognition and analysis. Clearly visi- All consumption data are available in the ERP/MES
ble instructions and color-coded weigh process results system without manual interaction. Based on this data
can help ensure a straightforward and efficient pro- exchange stock levels are automatically adjusted.
cess that increases accurate throughput. Seamless exchange supports batch release in the
MES/ERP system, simplifies data handling and avoids
Security plays a role here, too: Only trained and autho- manual input errors.
rized users are be able to manage materials via user
rights configured to their processor status. Additionally,
if an ingredient entry scanned and checked against
the recipe does not match, the system can reject it and
produce an error message, reducing human-error risk.
Steps become immediately traceable. Hazardous ma-
terials precautions can also be clearly indicated when
necessary.

Ease-of-use considerations reduce time spent in train-

ing. Standard log-in/lock-out procedures also reduce
unproductive downtime between operator shifts and
enhance security.
After successful log-in, planned production orders are presented to
the operator

METTLER TOLEDO © 11/2016 - Formulation 15

Formulation

Barcodes guarantee simple, fast verification with the connected reader

4 Integrated Traceability

In every production step from goods entry to shipment, • Weighing labels. Dispensed materials for an order
database entries correspond to in-process materials. are marked. Order, batch and lot number help guar-
In a computerized system, barcode-reader enabled la- antee processors do not mistake components.
bels assist with component identification and overall
traceability during processing. • Pallet labels. These identify a pallet and its contents,
particularly when materials are placed on a pallet
before they are moved into production.

Scans help avoid confusion as materials are brought

into production and ensure that the right material is
added to a mixture at the right moment. Recorded re-
sults help manage stock, FEFO (first expired, first out),
overall inventory and enhance process transparency.

A newly printed weighing label helps

guarantee component identification

Printers connected to weighing workstations can print

labels at the point of identification that enable fast ma-
terials recognition. Label types include:

• Stock labels. These ensure stock is known upon ar-

rival and becomes traceable. Descriptions, lot num-
bers, quantity, delivery date, expiry and status is en-
tered. The material enters the database and is Company logo and safety / danger symbols, as well as important
available for processing. status information

16 METTLER TOLEDO © 11/2016 - Formulation

 5 Summary

In an era of modern threat to food safety as well as ponents flow into the production process timely and
increased regulatory scrutiny, a well-designed, com- that available materials are fully exploited. The results
Formulation

puter-guided formulation and weighing process are less waste, less rework, less recycling, and low-
results in straightforward, efficient and fully traceable ered production costs. Productivity is significantly im-
food production. proved at the same time compliance with international
regulations regarding materials traceability is assured.
With easily integrated, standardized weigh stations,
label printers and barcode scanners, materials mix- Enhanced output and higher yield from available raw
ups and wrong quantities become history. The result- materials should result in ROI on initial system invest-
ing active stock management makes sure that com- ment in 12 or fewer months.

6 Additional Resources

• 21 CFR Part 111

Controls Used for Manufacturing, Processing, Packing, or Holding Dietary Supplements for FDA 21 CFR Part
111 CGMP Regulations – www.mastercontrol.com/regulations/21_cfr_part_111.html

• Regulation (EC) No 178/2002 of the European Parliament and of the Council of 28 January 2002
This European regulation lays down the general principles and requirements of food law,
establishing the European Food Safety Authority and procedures in matters of food safety –
www.food.gov.uk/multimedia/pdfs/1782002ecregulation.pdf

• www.mt.com/formulation

Mettler-Toledo GmbH
Industrial Division
www.mt.com/ind-food-guides
CH-8606 Nänikon, Switzerland For more information
Tel. + 41 44 944 22 11

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364113 / Marcom Industrial
17
 Advanced Batch Control
Batching
for Increased Process Transparency

Batch production is one of three main types of manufacturing processes, used to turn
raw materials into finished goods. It can be defined as:
• Starting with input materials
• Subjecting them to an ordered set of processing activities
• Creating a new output material

An accurate, reliable weighing system that measures

ingredients and transfers them into the batch is a criti-
cal part of the process. This process can be automat-
ed, manual, or a blend of both.

Realistically, automated transfer and batch control can

be managed at the weigh terminal instead of a full-
scale PLC or DCS control system. The right weigh ter-
minal/system can also guide manual batching. A
stand-alone batch control system may be of particular
benefit in smaller-scale operations because it elimi-
nates the processing time and cost associated with
PLC programming.

This paper will explore benefits of stand-alone batch

control and discuss ways they help:
• Achieve consistent results Contents
• Increase efficiency 1 The Need for Dedicated Batch Control
• Lower costs
2 Batch Control System Selection
Considerations
Ultimately, consistent results increase customer satis-
faction and make it easier to meet processing or prod- 3 Implementing Dedicated Batch Control
uct certification standards. The right solution will give 4 Summary
rise to process transparency while simultaneously im- 5 Additional Resources
proving a company’s bottom line.

18
 1 The Need for Dedicated Batch Control
An example of batch control most people can relate to The batch control scenario has changed significantly.
is baking bread. Raw recipe materials are lined up A batch control solution to manage batch-to-batch
Batching

then combined in an ordered fashion. Tools such mea- consistency is critical to ensure high product quality.
suring spoons, mixers, and heat transform the raw Investment in a well-designed batch control system to
materials into a new output material – a fresh, deli- manage this larger-scale manufacturing scenario can
cious loaf of bread. also help:
• Increase throughput
This example is simplified, but it translates to the man- • Reduce raw materials waste
ufacturing environment. Only now, imagine hundreds or • Eliminate end product variations
even thousands of bread loaves being baked every • Maximize overall efficiency
day. There may even be variations in forms and flavors.

2 Batch Control System Selection Considerations

When faced with selecting the right batch control sys- The International Society of Automation (ISA) S88
tem for a particular process, the task may seem Batch Control (Part 1-4) provides a consistent batch
daunting: How can it be established that the selected standard that can help manage the batch application,
system will improve production efficiency, eliminate no matter what kind of solution is chosen. Having a
raw material losses, and improve output consistency? controller that has the S88 guidelines built in allows
the user to have a modular system that will provide a
The overall solution must manage the various types of consistent application of the control system across
material transfer onto the weigh platform and weigh multiple locations, which can minimize training re-
each ingredient. A weigh terminal that can manage quirements, simplify user interface and allow multi-
both activities lends itself to batching applications and plant installations to share recipes and information
can help a control engineer simplify processes, since about their process in the same data structure. With a
ingredient weighing and material transfer are essen- PLC solution careful programming and implementation
tially two parts of a single action. would be required to ensure that a consistent ap-
proach was followed, especially in multi-plant installa-
A PLC system can be applied effectively, particularly in tions.
instances when the batch process is fixed – producing
the same end product – and does not see a great deal A dedicated batch control solution, on the other hand,
of switching between ingredients and recipes. Howev- will combine batch management and material transfer
er, this may not be the best solution for the small to technology into one, full-featured batch controller. This
mid-size operation that requires flexibility in their pro- eliminates the need for PLC code writing, reduces
cess because of limited resources. start-up time and allows the customer to focus on their
areas of expertise: their unique, palatable recipe.

METTLER TOLEDO © 11/2016 - Batching 19

 3 Implementing Dedicated Batch Control

Selection of a dedicated system that follows a docu- Batch control/reliable weighing

mented structure for equipment handling, I/O control, Having consistent guidelines at the center of a batch
Batching

and material paths/recipes in the production process process can help lower production costs, increase
can produce immediate and measurable benefits. throughput, improve yield, reduce material loss, and
The ISA S88 batch standard provides a helpful guide increase batch equipment utilization.
to this selection by:
• Defining a useful batch control model Following the S88 standard separates the physical
• Communicating common batch control requirements equipment from the recipe. This allows flexibility in
• Offering helpful configuration information system configuration and makes switchover time from
• Guiding vendor solution integration recipe to recipe much shorter, which helps increase
throughput. The standard also provides an operator
The high-level objective of S88 is helping batch pro- with a consistent interface, which helps increase
ducers make consistent, repeatable batches. The stan- familiarity with and utilization of the equipment. Mate-
dard provides common terminology for batch manu- rial loss is minimized because the operator is prompt-
facturing as well as guidelines on how to recover from ed through each ingredient addition. A user interface
upsets during batch processes. allows each material to be added within an allowable
tolerance range.

Ideally, a batch controller will take the S88 batch stan-

dard into account out of the box to simplify batch con-
trol implementation. A reliable weigh terminal such as
IND780batch will also be integrated into the solution.

Material 3

Fast feed
Fine feed Material 5

Fast feed
Material 2 Fine feed

Fast feed
Fine feed Material 4

Fast feed
Material 1 Fine feed

Fast feed Hand add

Fine feed

IND780batch
Mixer terminal

Scale

Discharge material

To storage tank Operator

Example of a multi-material, 2 speed feed automatic material transfer Batch installation

20 METTLER TOLEDO © 11/2016 - Batching

 Achieving automated targets batching. However, adding a batch control system to
The S88 standard outlines a modular, flexible process guide the operator can eliminate problems with over-
that allows a user to simplify a batch process. An inte- and under-filling and ensure that unnecessary ingredi-
grated, stand-alone solution supports this flexibility by ents are not added or necessary ones missed.
pre-defining the process equipment and letting the op- Generally, the operator will use a bar code scanner to
Batching

erator select from several different recipes, shortening identify an ingredient, add it, and move on to the next.
the time to switch from batch to batch. It also provides Material validation alerts the operator when an incor-
central control of material transfer using machinery rect material is chosen and provides a prompt to scan
such as feed valves, gates, and screw conveyors while for the correct ingredient to ensure batch consistency.
simultaneously monitoring weight to ensure accurate
target cutoff of each transferred material. This can dra- In a blended approach, the operator may start a batch.
matically improve batch throughput and reduce mate- Then, the rest of the process runs without user inter-
rial waste. vention unless additional hand-added ingredients are
needed.
Manual processes & batch control
If the process is manual – with an operator selecting If the process includes automatic material transfers,
and adding ingredients – typically no discrete I/O is then a batch controller that allows assigning I/O to
associated with control. This method is highly flexible manage the material feeds is required. Usually, there
since there is no associated I/O and several different are also auxiliary equipment pieces that require man-
materials can be batched without preconditions. agement.
In a manual process, the operator typically manages

Barcode scanner
Hand add
facilitates tracking and
up to 999 materials
traceability
per recipe

Bench scale
IND780batch
terminal
guides operator
through recipe with
on-screen prompts

Example of a multi-material, manual formulation Batch installation

METTLER TOLEDO © 11/2016 - Batching 21

 Auxiliary equipment management This allows investigation into potential performance
Control of auxiliary equipment may require certain cri- problems. Managers can check for evidence of pro-
teria to operate properly. For example, if a mixer is re- duction changes. This helps with easy batch and raw
quired, the batch controller may need to be able to: material identification and can help:
• Turn on the mixer at a specific recipe step • Determine why a batch may have been “off,”
Batching

• Pulse the mixer for a certain amount of time • Pinpoint the ingredient that caused the problem
• Delay starting the mixer until an add-by-hand ingre- • Minimize number and extent of recalls
dient is placed on the scale before the mix starts • Allow users to approach vendors who supplied the
ingredient
No matter the type of batch control being used, a con-
troller that accurately handles material transfers, pro- A stand-alone batch control processor should be able
vides accurate target cutoffs, minimizes overfeed/un- to incorporate track-and-trace functionality, as well as
derfeed scenarios, and manages the batch process is handle recipe creation and storage, backup terminal
required for batch-to-batch consistency. settings and collect data. These actions are to:
• Implement a defined recipe-creation sequence
Track and Trace/Data Collection • Edit ingredients or amounts
Another desirable element for a batch controller is the • Re-scale the entire batch
ability to track and trace phases in the batch process
to identify: Using a dedicated, stand-alone batch control solution
• When a product was made that accommodates the above functionalities can sig-
• What and how much material was used nificantly improve batch repeatability and productivity
• Which operator ran the particular batch while controlling costs. METTLER TOLEDO offers this
type of robust functionality in various stand-alone and
easy to integrate batch controllers.

PC configuration tool for Batch appli-

cation allows off-line recipe creation
and system configuration.

22 METTLER TOLEDO © 11/2016 - Batching

 4 Summary

Implementing batch control management capabilities • Adhere to the S88 batch standard for process flexi-
can help achieve advanced material transfer and pro- bility and quality maintenance
Batching

cess control goals. Using an out-of-the-box solution • Increase material transfer throughput and improve
that integrates weighing and material transfer can pro- feed accuracy
vide powerful cost and time savings for smaller-scale • Provide track and trace/data collection to manage
producers who may not have the resources to imple- risk and minimize waste
ment a PLC with its requisite programming expertise
and time. The right stand-alone solution can run multiple batch
processes while eliminating complex PLC reconfigura-
Ideally, any chosen solution will: tion when a customer’s needs change. The resulting
• Provide dedicated batch control for both manual and tighter control can make products more consistent.
automatic batching This can increase customer satisfaction and loyalty
• Contain control logic in the measurement instrument while simultaneously improving productivity and en-
for faster I/O hancing the bottom line.

5 Additional Resources

The following links and papers can provide more information on industrial weighing solutions and how effective
batch control can enhance quality, improve materials use rates, and lower production costs.

• METTLER TOLEDO Batching • Control Global

www.mt.com/batching www.controlglobal.com

• International Society of Automation • Functions that need to be considered in for Material

www.isa.org Feed (Transfer) Batch Controls; Charlie Fu Ph.D,
Technology Leader, Procter & Gamble
• Applying S88, Batch Control from a User’s
perspective; Jim Parshall and Larry Lamb – • World Batch Forum
ISBN #1-55617-703-8 www.wbf.org

• Batch Control Systems, Design, Application,

and Implementation 2nd Edition; William Hawkins
and Thomas Fisher – ISBN # 1-55617-967-7

Mettler-Toledo GmbH
Industrial Division
www.mt.com/ind-food-guides
CH-8606 Nänikon, Switzerland For more information
Tel. + 41 44 944 22 11

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364126 / Marcom Industrial
23
 Inventory Control
Inventory Control
Tank & Silo Weighing

Gravimetric level control is one of the most accurate inventory control methods
available. Its high degree of accuracy makes it particularly helpful when mea-
suring high-value solids, liquids and sometimes even gases. Because load cells
are placed outside of the tank, gravimetric level control it is perfect for measur-
ing aggressive, hot, frozen, non-free-flowing or non-self-leveling materials.

Tank/silo weighing is preferred in many applications for

other reasons as well. Because of the system’s inherent
design, operators never need to handle materials being
weighed. This makes it almost impossible to contami-
nate stored materials. Also, results are independent of
tank shape, measured materials, or process parame-
ters such as temperature or material viscosity.

A well designed, properly installed system has very low

maintenance requirements and promises long life. On
a typical one-year maintenance and calibration cycle,
a moderately used tank scale provides decades of reli-
able inventory control and weighing.

This paper further explores the benefits of tank/silo

weighing as well as points to consider for their optimi-
zation. Contents
1 Advantages of Gravimetric Level Control
2 Tank Scale Design
3 Tank Scale Installation
4 Weighing Terminals and Transmitters
5 Predictive Maintenance Weigh Modules
6 Frequent Maintenance
7 Summary
8 Additional Resources

24
 1 Advantages of Gravimetric Level Control

Highly effective inventory management can be ob- other technologies. The entire maintenance is possible
tained using gravimetric level control. This is primarily without getting into contact with the material or the in-
Inventory Control

because tank-based gravimetric inventory control is side of the tank. Thus the tank can be optimized for
independent of many influences that other technolo- hygienic aspects and low contamination thread.
gies must cope with.
Free choice of tank material
Tank design can be optimized for the material that will Manufacturers have the ability to choose the most suit-
be measured. Therefore, gravimetric inventory control able tank material and surface quality without com-
offers a great deal of production flexibility. Materials promising accuracy. This simplifies the design phase
and other process parameters such as temperature, and construction of food-grade tanks and silos.
viscosity, density and pressure can be changed with-
out recalibration or sensor adjustment. Flexible with always accurate results
Tank weighing provides a high level of flexibility in a
Accuracy weighing process. Results are independent of:
The gravimetric method provides the best accuracy • Tank shape: Gravimetric inventory control works
combined with high flexibility for inventory control over with all tank shapes, which allows material flow
a long time. The accuracy is independant from materi- to be optimized without compromising sensor
al characteristics such as density, di-electricity, shape, requirements.
flow-behavior, temperature, dust or foam. Even simple • Measured material: Gravimetric inventory control is
systems achieve accuracy levels of one percent or bet- independent of material. It works with liquids, high
ter. Accuracy can be as good as 0.1 percent of applied viscosity liquids, grind materials, sticky bulk materi-
load in optimized systems. No other inventory control als, foam, etc. Change of material does not require
technology for tanks comes close to this level of opti- recalibration or sensor changes, which adds to the
mized material use. method’s flexibility. It is possible to measure input of
different materials in batching or mixing processes.
Capacity • Process parameters: Changes of temperature, pres-
Single load cells and weigh modules are available sure, density and viscosity do not influence the re-
from a few kilograms to several hundred tons. Multiple sult. Gravimetric level control always works.
cells or modules can be arranged under one tank for a
net capacity of several thousand tons. One single measuring technology
for the entire process
Ruggedness One common level/mass control technology for the
Load cells can be integrated into complete weigh mod- entire process is possible. This reduces training needs
ules with factory adjusted overload protection. Dedi- for operators and maintenance to understand function-
cated mechanisms protect the load cells from damage ality, calibration and limits of many different sensor
due to under load coming from the effects of wind technologies.
forces. The tank can even be protected from tipping
over in case of earthquakes or very strong wind forces. Long life – low maintenance requirements
Stabilizers protect the load cells from torsion effects Gravimetric sensors and their so-called load cells are
which result from mixers inside of the tank. low-maintenance parts. They require less calibration
than many other inventory control technologies. De-
Hygiene pending on environment conditions, proper installation
Gravimetric inventory control requires no direct product and protection measures, load cells can last for de-
contact with the sensor. No special access to the silo cades with no performance loss.
or direct contact with material is required as it is with

METTLER TOLEDO © 11/2016 - Inventory Control 25

 2 Tank Scale Design

Weigh modules help easily convert almost any tank, Whether compression or tension weigh modules are
hopper or silo into a scale. They contain all features used depends on the specific application. The chart
Inventory Control

required for load cell accuracy as well as safe opera- below provides an overview of general design consid-
tion, including the ability to operate under the effects erations affecting the choice of weigh modules.
of various temperatures.

There are two basic types of weigh modules:

• Compression weigh modules are designed so that a

tank or other structure can be mounted on top of the
weigh modules.

• Tension weigh modules are designed so that a tank

or other structure can hang from the weigh modules.

METTLER TOLEDO Compression Weigh Modules METTLER TOLEDO Tension Weigh Modules

Design consideration Compression weigh modules Tension weigh modules

Floor Space Requires enough floor space to accommodate Requires no floor space and can be suspended to
tank size. Might require buffer space around tank allow free movement beneath tank
Structual Restrictions Weak floors might require additional construction Weak overhead supports/cellings might require
or a special installation to accommodate weight additional construction or special installation to
of filled tank accommodate weight of filled tank
Weight Limit Generally unlimited. Even load distribution is in- Tension weigh modules are available up to 10t
herent with three vesel supports, and is increas- (20,000lb). This and structure considerations
ingly difficult to achieve as the number of weigh limit tension system capacity
modules grows beyond four
Load Cell Alignment Designs may vary and must consider floor de- Cell alignment will not vary significantly because
flection, available support beams, and tank size, tension rods and other support equipment tend to
shape, and condition accommodate most deflections

A tank scale’s support structure should deflect as little Numbers of weigh modules needed
as possible, and any deflection should be uniform at For an existing installation, the number of supports de-
all support points. Excessive deflection can cause inlet termines the number of weigh modules. If a tank has
and outlet piping to bend, creating accuracy errors. four legs, four weigh modules are required.

26 METTLER TOLEDO © 11/2016 - Inventory Control

 For new installations, a three-point support system is
preferred. Using a three-point system, correct load dis-
Inventory Control

tribution on the weigh modules is assured. However, if

wind, fluid sloshing, or seismic loading factor into op-
erations, the tank might require four or more supports
for additional stability and protection against tipping.

Design considerations
in context with calibration
The method of calibration has to be determined before
start of design since there are three different methods
which influence design of tanks and silos.
A full capacity calibration with certified weighs trace-
able to the national standard ensures best accuracy
and reduces risks. This method is applied for expen-
sive material.

A step calibration is applied in using test weight of

20% of full capacity. After the first step of calibration,
the test weight is taken off and substituted by water or allowing for mathematical system calibration. A dedi-
any other suitable substitute. In the second calibration cated weighing electronic is configured with these val-
step, the test weights are added again to reach a total ues on site to substitute calibration with weights.
of 40%. In the third step, test weight is substituted
again. This procedure is repeated until 100% of full The full capacity and the step calibration require fix-
capacity is reached. tures to hang or place weights with an equal distribu-
tion on the tank. The application of the CalFree method
The METTLER TOLEDO CalFREE™ method ensures rea- requires weight transmitters or weighing terminals with
sonable accuracy without using weights on site. Load the capability to input the deviation values of the
cells are delivered with a factory calibration certificate, load cells.

3 Tank Scale Installation

A tank scale’s accuracy and safety depends on correct material is stored or a high risk is related in case of in-
installation and calibration. Modern weigh modules accurate results.
protect the load cell from overloading during installa-
tion. In very rough installation environment it is recom- It is recommended that technicians with experience in
mended to use the WM as a dead stand without load weighing technology handle initial calibration in order
cell and install the load cell shortly before operation to achieve optimum accuracy and safety. The initial
starts. An initial calibration with at least 20 % of full calibration should be certified. Such a document con-
load in using certified weights which are traceable to firms correct installation and calibration right from the
the national standard is recommended. A step or even beginning of operation.
full load calibration should be performed if expensive

METTLER TOLEDO © 11/2016 - Inventory Control 27

 4 Weighing Terminals and Transmitters

Simple weighing terminals display the weight. Trans- ogy to eliminate effects from sloshing liquids, en-
mitters just transmit the weight via serial interface vironmental vibrations or mixers. The terminal with
Inventory Control

or Fieldbus to a PLC or ERP. However, advanced METTLER TOLEDO CalFREE™ enables calibration
weighing terminals don’t only display and transmit without weights. This can save installation and repair
weight. They also play an important role in providing cost for applications with low accuracy and no trace-
accurate results if they have advanced filter technol- ability requirements.

5 Predictive Maintenance Weigh Modules

Advanced PowerMount™ Weigh Modules use load

cells with incorporated micro processors. They are
connected with plug-and-play connectors without
need for junction boxes.

Such an intelligent weighing system continuously

monitors status and performance of the load cells and
alarms operator if accuracy is threatened. RunFlat can
PowerMount
substitute a defective load cell to allow continuation of Weigh Module for
batch processing until replacement. Action can take Predictive Maintenance
place before significant quality costs occur. Further-
more, installation and repair are greatly eased with mostly done without re-calibration which saves down-
such a system. The replacement of single load cells is time and calibration effort.

6 Frequent Maintenance

Regular maintenance of weighing equipment is minals. They will also perform load tests with certified
recommended. weights which are traceable to the national standard
and recalibrate the modules if necessary. With this
A 1-year interval at 20 % of full load is adequate for minimum amount of maintenance effort, a tank scale
many applications. However, a maintenance schedule typically works trouble-free for decades.
should always be based on a thorough risk assess-
ment that takes into account impacts of incorrect re- Advanced weighing terminals and transmitters offer
sults, minimum weight, and raw material costs. predictive maintenance functions, permanently
METTLER TOLEDO provides proven, professional meth- checking load cell signals for abnormalities.
ods for determining optimal calibration.

During regular maintenance visits, experts check the

status of load cells, connection boxes, cables and ter-

28 METTLER TOLEDO © 11/2016 - Inventory Control

 7 Summary
Gravimetric level control using tank scales is one of the tion. More may be considered when other process
most accurate methods to determine inventory level. It parameters come into play.
Inventory Control

provides maximum freedom to optimize tanks to mate-

rial and process while also allowing a high degree of Advanced PowerMount™ weigh modules offer predic-
flexibility surrounding materials being managed. tive maintenance functions which permanently monitor
the load cells for abnormalities to warn an operator or
Pristine hygiene and process flexibility are inherent the control system before failures occur.
in tank/silo weighing. Parameters such as mate-
rial temperature, density and viscosity do not affect Maintenance requirements of tank/silo weigh modules
results, so recalibration and sensor changes are not are few. A well-designed system working in moderate en-
required when changing materials or recipe formu- vironmental conditions only requires testing and calibra-
lations. This flexibility also enhances the method’s tion once a year and provides decades of reliable use.
cost-effectiveness.
With gravimetric measuring, one technology can be
The choices of compression versus tension weigh used for all tanks and all materials plus many other ap-
modules, as well as the number of weigh modules re- plications on the production line. METTLER TOLEDO can
quired, is determined by application and current use help with a complete range of products, including weigh
considerations. For new systems, a three-point weigh modules, installations and maintenance through a vari-
module design is preferred for balanced load distribu- ety of engineering documents and service capabilities.

8 Additional Resources
• METTLER TOLEDO’s Tank/Silo weighing • Download comprehensive engineering documents
www.mt.com/tank-weighing www.mt.com/ind-system-handbook

• METTLER TOLEDO Weigh module offering

www.mt.com/weighmodules

Mettler-Toledo GmbH
Industrial Division
www.mt.com/ind-food-guides
CH-8606 Nänikon, Switzerland For more information
Tel. + 41 44 944 22 11

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364128 / Marcom Industrial
29
 Ergonomic Manual Portioning
Manual Portioning
u

Employees in a food factory, who are checkweighing and portioning tons of food every
day, are under constant pressure to efficiently fulfill their daily weighing tasks. These
repetitive tasks deserve solutions that not only support workers' health, but also speed
and accuracy. An ergonomic scale fits the bill.

u
u
u
u u
u
u u
u u
u
u

u
u u
u

As a result, manufacturers benefit through:

u Contents
• Higher throughput rates 1 Ergonomics Considered
u
2 Manual Checkweighing and Portioning
u u u
weighing task and offers suggestions for installing 4 Specialized Tools can Enhance
Operator Interaction
u
u
6 Additional resources
u u

30
 1 Ergonomics Considered
u u u
u
Manual Portioning

u
u
u u u
Describe the task u u
u u u

Simplify the task

u
u u

u u

Use ergonomic tools

Use ergonomic tools

2 Manual Checkweighing and Portioning

u u u u
u u u u

u u u
u u u u

• Portioning from bulk container beside the scale

• Portioning from bulk container on the scale

METTLER TOLEDO © 11/2016 - Manual Portioning 31

 3 Simplification through Smart Functionality

u u u
Manual Portioning

Basic weighing
Classic approach The operator places the item on the scale and checks if the dis
u
Basic checkweighing scale

+ Reduced operator errors

+ Higher throughput
– Targets and tolerances need to be entered

Classic speed

Portioning from bulk container beside the scale

Classic approach u
u

u u

Checkweighing scales u u u
u
u
u
u
+ All from above plus
+ Reduced operator errors, less eye strain
Increased speed + No single keystroke required

Portioning from bulk container on the scale (take-away mode)

Classic approach u u
u

Scales with take away mode u u

u u
u u
u u
u u

+ All from above plus

+ Fastest portioning process
High speed + Less operation steps needed

32 METTLER TOLEDO © 11/2016 - Manual Portioning

 4 Specialized Tools can Enhance Operator Interaction

u u
Manual Portioning

Operator posture

u u u
u u u u u

u u
u u
u u
u u
u

Design of a console workstation for a stan

u u

Displays

Specialized scale features can enhance operator interaction with the work

METTLER TOLEDO’s colorWeight®

®
changes the color of the screen to indicate

u u u u
u

colorWeight®
des a clear read on whether or not weight
is within tolerance

METTLER TOLEDO © 11/2016 - Manual Portioning 33

 Mobile weighing

u
Manual Portioning

u u u
u u u
u

Efficient data handling

u
u

Store data on the terminal

Data and weighing parameters can be entered and stored outside of the
u
u u

u u
u

Manage your data from a PC

u u
u u
u u
u
u
u

Transfer data wirelessly

u u

u
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Work breaks

u u u
u
u u u

34 METTLER TOLEDO © 11/2016 - Manual Portioning

 5 Summary
u u
the manufacturer’s chosen checkweighing procedure and breaking it into individual components is the
Manual Portioning

u u u u u u u

6 Additional Resources

u u u u
• METTLER TOLEDO Over/Under Checkweighers
www.mt.com/over-under-checkweighers
®
u
www.mt.com/ind-operator-efficiency
• colorWeight® Value Calculator
www.mt.com/ind-colorweight-calculator

Mettler-Toledo GmbH
Industrial Division
www.mt.com/ind-food-guides
For more information

www.mt.com/contacts

35
 7 Considerations for Cleaning Production
Cleaning Production
Equipment in Hygienically Sensitive Environments

Scales, used in hygienically sensitive industries, such as the meat industry, are often
in direct contact with the product. They are consequently a potential contamination risk.
Independently, if they are used in a basic weighing application in the goods entrance
or as a checkweighing solution in the packaging area, they are located in hygienically
sensitive areas that follow strict sanitation procedures.

Such an equipment sanitation procedure has to ensure

adequate cleaning of product-contact and product
non-contact surfaces. A common sanitization standard
for contamination reduction of food-contact surfaces is
generally accepted as 99.999% achieved in 30 sec-
onds. The sanitization standard for non-food contact
surfaces is accepted as a reduction of 99.9% [1].

Disinfection, in contrast, must destroy or irreversibly

inactivate all specified organisms within a certain time,
usually 10 minutes [2].

To achieve those requirements, the equipment has to

be hygienically designed and efficiently treated during
the sanitation program. This white paper provides
guidance on where to focus when cleaning equipment, Contents
such as scales and checkweighers, and provides a 1 Choose a Hygienically Designed Scale
typical example of a sanitation plan.
2 Prepare a Surface for Sanitizing
3 Cleaning with Detergents
4 Visual Controls
5 Disinfection
6 Final Rinsing
7 Verification of Procedures
8 Summary

36
 1 Choose a Hygienically Designed Scale
An effective and efficient cleaning starts with the But what construction elements are relevant if
right equipment. Available on the market are scales such an approval is missing? Consider the
Cleaning Production

that have the European Hygienic Engineering and following points when selecting a scale for a
Design Group (EHEDG) and National Sanitation hygienically sensitive environment [3].
Foundation (NSF) approval for hygienic design.

Topic Considerations
Cleanable to a microbiological level
The equipment should be designed to prevent bacte- • All surfaces are accessible for mechanical clean-
rial ingress, survival, growth and reproduction on ing and treatment to prevent biofilms formation
both product and non-product contact surfaces of
the equipment.
Made of compatible materials
Construction materials must be completely compat- • All surfaces should be designed to eliminate water
ible with the product and environment. Water collec- pooling and should be self- draining
tion points have to be avoided. • Product contact surfaces must be made with
materials which are corrosion resistant e.g. stain-
less steel
• Hollow areas must be eliminated
• Equipment parts should be free of niches nooks,
such as pits or cracks
• Check materials against FDA components list of
food contact materials [8]
Accessible for inspection, maintenance, cleaning and sanitation
All parts of the equipment shall be readily accessible • Bench scale: Lift the platter for cleaning
for inspection, maintenance, cleaning and sanitation • Floor scale: Easy to lift platter or scale
without the use of tools.
Sanitary operational performance
During normal operations, the equipment must per- • Buttons on control panels have to be cleaned and
form so that it does not contribute to unsanitary con- sanitized during operations (risk: microbial har-
ditions or the harborage and growth of bacteria. borage)
Hygienic design of maintenance enclosures
Maintenance enclosures and human machine inter- • Maintenance enclosures in direct wash-down
faces, such as push buttons, switches and touch- areas must be able to be exposed to water
screens, must be designed to ensure that product • Securing with a plastic bag is not acceptable.
residue or water does not penetrate or accumulate in Should be NEMA and IP rated, including high-
and on the enclosure or interface. pressure washing
(Scale design principles, adapted from 10 Principles of Sanitary Design, AMI Foundation)

METTLER TOLEDO © 11/2016 - Hygenic Design 37

 2 Prepare a Surface for Sanitizing

Preliminary cleaning is an important operation and is substantially reduces the number of other undesir-
aimed to achieve visual cleanliness of the equipment. able organisms, and does not adversely affect the
Cleaning Production

product or its safety for the consumer. Sanitizing

Prepare a surface for sanitizing does not affect bacterial spores – that is beyond the
For a sanitizer to be effective, the surface being sani- capability of the process.
tized must be physically clean. One cannot sanitize a
dirty surface – organic soils will consume the sanitiz- Non-food contact surfaces
er. Detergent residues must be rinsed well – they will Non-food contact surfaces shall be free of unneces-
neutralize many sanitizers. Spraying a surface with a sary ledges, projections and crevices, and de-
sanitizing solution without first cleaning the surface signed and constructed to allow easy cleaning and
properly is a waste of time and money. [2] to facilitate maintenance. Although usually the regu-
lations do not explicitly address potential indirect
Sanitation food-contact surfaces food-contact surfaces, such as terminals, these
Sanitizing of food-contact surfaces aims to mini- surfaces can be an important source of microbial
mize disease producing bacteria and viruses, contaminants.

Relevant non-food contact surfaces

Bench scale platforms

Remove the platter: The daily cleaning procedure should include all parts under-
neath the platter and the feet. [7]

Floor scales
Look underneath the platter: Choose floor scales that can easily be cleaned
underneath the platter. Different types of floor scales offer the capability to only lift
the platter or the complete scale. Another good alternative are mobile floor scales. [7]

Terminals
Buttons on control panels should be cleaned in order to avoid microbial harbor-
age or biofilm.

Checkweighers
An open construction for cleaning and visual inspection is important, including
a toolless removal of components and high ground clearance.

38 METTLER TOLEDO © 11/2016 - Hygenic Design

 3 Cleaning with Detergents
After removing food debris and rinsing with water, the • Alkalis (sodium,
standard cleaning procedure with detergents includes potassium, etc.)
Cleaning Production

the following procedures: are active

against organic
• Cleaning with alkali detergents soiling, as they
Daily: Application of chlor-alcalic foam with low saponify fats
pressure and dissolve
Once a week: Application of acid foam proteins. Conse-
Consider the instruction of the detergent supplier re- quently, these
garding concentration and temperature, because the products are
effectiveness of the detergents depends on the tem- frequently used
perature used and duration of application. in the meat and
• Rinse with water after the predefined contact time. poultry indus-
tries.
• Acids are used
Which detergent and sanitizer to apply? mainly to eliminate calcium deposits (from hard wa-
This cleaning involves the use of a product with deter- ter) and to restore stainless-steel surfaces.
gent action, approved for cleaning with food-contact • Organic (surface-active) products are often incorpo-
surfaces. The choice of cleaning product depends on rated into the alkali and acid preparations mentioned
the principal type of soil present and the equipment above. Those products have the ability to reduce the
used. Such products may be divided into the following surface tension of water, inhibiting the tendency for
broad categories: droplets to form on cleaned surfaces. [4]

4 Visual Controls

Check visually if all surfaces now look clean and correct if necessary.

5 Disinfection

The aim of disinfection is to eliminate the microor- It includes:

ganisms still present on surfaces, adhering to an-
chorage points. Some bacteria become attached a • Daily: Cleaning with disinfectants
few nanometers from the surface, while others pro- Contact time and pressure wash-down require-
duce substances that result in an adhesion that is ments depend on the product and are defined
difficult to break down (biofilm) [4]. in the manuals of the suppliers.

METTLER TOLEDO © 11/2016 - Hygenic Design 39

 6 Final Rinsing

This is a relevant step to remove all traces of soil, detergents and disinfection substances,
which may get in contact with food.
Cleaning Production

Sanitation plan
A common sanitation plan for the meat industry is described below:

SOP Page 1 of 1
Version 1 Production (8-10°C) Valuable from:
04.06.2015
Document issued by
SealedAir

Cleaning plan
Machine / object Interval Product Application Remarks
Mo / Tues / Wed / Fri
After each usage

Time [min.]
Temp. [°C]
Conc. [%]
Thursday

Monthly
Weekly

Tables / walls / floor x Water Remove debris, pre-rinse and

rinse after foaming
x Enduro Chlor 3 40 15 Chlor-alcalic foam

x Aciclean VK39 3 40 15 Acid foam

x Suredis VT1 1 20 15 Disinfection

x Water Rinse after each disinfection

Scales / equipment x Water Remove debris, pre-rinse and

rinse after foaming
x Enduro Chlor 3 40 15 Chlor-alcalic foam

x Aciclean VK39 3 40 15 Acid foam

x Suredis VT1 1 20 15 Disinfection

x Water Rinse after each disinfection

Chlor-alcalic
Acid
Alcalic
Neutral

40 METTLER TOLEDO © 11/2016 - Hygenic Design

 7 Verification of Procedures

Upon completion of sanitation, you need to verify that Further protein residue or microbiological tests can be
the procedures have been effective. The simplest ap- performed using contact plates or swaps. [6]
Cleaning Production

proach is a visual assessment that no debris remains.

8 Summary

Production equipment, such as bench and floor scale for such an area and provides guidance on
scales, are often installed in hygienically sensitive en- how to specifically treat food-contact and non-food
vironments in a production plant and should be contact surfaces. It shows most relevant cleaning steps
cleaned according to strict sanitation plans. This paper and contains a detailed sanitation plan for a daily and
highlights criteria to use when selecting a weighing weekly cleaning procedure in a meat factory.

Acknowledgement
[1]
Official Detergent Sanitizer Test, AOAC International Official Methods of Analysis 2009 AOAC International,
Gaithersburg, MD
[2]
Alan Parker, Effective cleaning and Sanitation Procedure, University of Maryland and the JohnsonDiversey
Corporation, 2007
[3]
Sanitary Design Equipment Principle, 10 principles of sanitary design, AMI, 2014
[4]
G. Salvat & P. Colin, Cleaning and disinfection practice in the meat industries of Europe,
Rev.sci. tech. Off.int. Epiz., 1995, 14
[5]
Pratical cleaning guidance for the meat industry, SealedAir, 2015
www.sealedair.com
[6]
Developing a Cost-effective Sanitation Plan for Small-to-medium Processors,
Keith Warriner, Ph.D. Food Safety Magazine, 2011
[7]
Examples of hygienically designed bench and floor scales
www.mt.com/ind-bench-floor-hygienic
[8]
FDA, determining the Regulatory Status of Components of a Food Contact Material,
www.fda.gov/Food/IngredientsPackagingLabeling/PackagingFCS/RegulatoryStatusFoodContactMaterial/de-
fault.htm

Mettler-Toledo GmbH
Industrial Division
www.mt.com/ind-food-guides
CH-8606 Nänikon, Switzerland For more information
Tel. + 41 44 944 22 11

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30259708 / Marcom Industrial
41
 Integrating Process Data
Data Connectivity
from Industrial Weighing

Efficient transfer of weighing process data to higher level MES or ERP systems can help
make manufacturing processes more transparent.

Increased transparency can improve asset use, reduce

operating costs, and make complying with certification
standards or industrial regulations easier. However,
identifying and implementing the most effective system
for data collection and integration can be challenging,
especially in a legacy manufacturing operation.

This paper explores weighing process integration

challenges and provides points to consider when
defining operating boundaries and data objectives.
Weighing and communication solutions are more
likely to meet objectives and produce measurable
ROI when these points are taken into account.

Contents
1 Defining Data Integration Challenges
2 Determining Data Integration Objectives
3 Assessing Data Integration Routes
4 Suggesting Best Practices
5 Troubleshooting Communications
6 Summary
7 Additional Resources

42
 1 Defining Data Integration Challenges

Challenges manufacturers face when effectively inte- • Optimized hardware

grating weighing data into an automated ERP/MES The ability to use solutions that integrate data from
Data Connectivity

system include: multiple scales into a single automated system.

• Speed • Easy of upgrading

The ability to deliver reliable, “filtered” weighing data Allowing for or replacing equipment with new con-
to a higher-level automation system during time- trollers that improve automation and data access
sensitive applications (such as high precision filling) capabilities.
so production adjustments can be made.
• Adverse conditions
• Flexibility High pressure wash-down; explosive/corrosive envi-
The ability to communicate information that affects ronments; high vibrations; electromagnetic interfer-
weighing accuracy, materials use and production ence and/or extreme temperatures.
rates such as product ID, target weight, tare weight,
scale status, operator messages, and error infor- An expert assessment of the conditions in which a
mation. weighing system is expected to perform, without loss
of accuracy or communications to the higher level
system, can help define operating boundaries.

2 Determining Data Integration Objectives

Before selecting a weighing terminal or communi- • What is the current communication medium?
cation system, an assessment of data integration Are there other viable options?
objectives must be made. Typical questions to • How might the data format requirements or the com-
answer include: munication medium evolve in the foreseeable future?
• What type of information will be communicated
between the weighing terminal and automation Several of these questions are strategic in nature:
system? what type of information is required, by whom, and to
• Who or what needs the data and why? what end? Once these questions have been answered,
• What triggers will be used to initiate data transfer, many options can be explored to meet, or potentially
and how frequently will communication be made? exceed the objectives. This pragmatic approach in-
• What are present data format requirements? creases the likelihood that once implemented, the
Are those requirements flexible? data integration solution will provide the best return
on investment.

3 Assessing Data Integration Routes

If PLC data integration is not required, PC-based serial vices. However, special care should be taken when im-
or Ethernet TCP/IP data communication are viable op- plementing Ethernet TCP/IP-based networks to ensure
tions. In comparison to PLC-to-PC communication, that mission-critical communication, data, and devices
lower cost Ethernet TCP/IP communication is feasible are adequately isolated from business networks. For
via widely available wired or wireless networking de- more information, see Best Practices, below.

METTLER TOLEDO © 11/2016 - Data Connectivity 43

 If PLC control is a prerequisite, the fieldbus chosen to In parallel to the PLC-to-terminal data exchange, an ad-
support process requirements can have a significant ditional connection (via serial or Ethernet TCP/IP) is
impact on the data integration objectives as well as the implemented between the terminal and a PC to achieve
project budget. The fieldbus assessment will determine additional data integration objectives.
the potential number of nodes, device types, and the
Data Connectivity

data capacity vs. transfer rate. The fieldbus choice, in For instance, a hybrid approach might include
combination with the choice of terminal, will also deter- • METTLER TOLEDO IND560 terminal including:
mine weighing data-related capabilities as follows: – EtherNet/IP™ fieldbus option for communication
• Upload of target weight data to the weighing terminal with a RSLogix PLC EtherNet/IP™-based system
• Download of calibration information and/or calibra- – Optional COMM2 Ethernet TCP/IP card for commu-
tion via a PLC program nicating with a back-office PC
• Download scale monitoring statistics
• Messaging options (cyclic, explicit, or both cyclic In this scenario, the terminal-to-PC communication
and explicit messaging) could support data integration to an OPC-compliant
server. OPC provides a standardized data format that
With the right combination of weighing terminal, field- can lower integration and support costs, reduce sys-
bus selection, and PLC system, all of the above capa- tem complexity, and speed up industrial automation
bilities are possible. project development. METTLER TOLEDO has partnered
with Kepware, developers of KepServer EX to jointly
A hybrid approach is also a viable option for achieving facilitate delivery of mission-critical weighing data into
additional data integration objectives. A PLC connection an OPC-compliant environment. See the list of "addi-
is leveraged to manage a critical production process and tional resources" at the end of this whitepaper for a
simultaneously communicate data, as outlined above. link to Kepware.

Here is a comparison of data integration requirements and limitations

via a few of the most common communication paths:
Communication method Requirements/limitations

Basic weighing data via • Limited communication of weight and/or rate

4-20mAor 0-10VDC signal • Separate communication between control system and weighing terminal for functions
such as zero or print commands

Basic weighing data via serial RS232/422 • Standard terminal data format with pre-defined, limited data sets
or Ethernet TCP/IP* • “Print template” stored in weighing terminal and communicated to external hardware
• Shared data server access via custom solutions

Weighing data via PLC fieldbus: • Requires PLC hardware/program to integrate data
EtherNet/IP™, DeviceNet™, Ethernet/IP®, • PLC interface capabilities limit data packet/message size
Profibus™ DP, Profinet IO®, CC-Link,
Modbus TCP

* NOTE: certain options outlined above are limited to specific terminals

44 METTLER TOLEDO © 11/2016 - Data Connectivity

 4 Suggesting Best Practices

Best practices for integrating weighing terminals with Unicast vs. Multicast communication can be found in
higher level systems will follow automation equipment ODVA publication 70, “Recommended Functionality for
Data Connectivity

supplier recommendations. While best practices for EtherNet/IP™ Devices,” which can be accessed using
every type of automation network is beyond the scope this paper’s concluding links.
of this paper, several best practices examples for im-
plementing ethernet-based networks such as EtherNet/ Minimize device load due to unwanted IP multicast
IP™, Modbus TCP™ or ProfiNet® follow. traffic. Depending on sub-net configuration and de-
vice connectivity, this objective can be achieved using
Industrial network vs. office network managed Ethernet switches supporting virtual LANs
Industrial network design requires different consider- (VLANs) and IP multicast routing.
ations from office network design. Traffic on an office
network, typically Ethernet TCP/IP-based, is non-deter- Minimize switch load due to unwanted IP multicast
ministic, or not highly time-critical. In a production traffic. Use full duplex, managed industrial network
network during a manufacturing process, data ex- switches capable of IGMP (Internet Group Multicast
change, consisting primarily of UDP/IP Unicast and Protocol) snooping, port mirroring, VLAN set-up,
Multicast packets, is highly time-critical. The cyclic SNMP statistical information, IP address blocking, au-
portion of the traffic on an EtherNet/IP™ network is to-restore of configurations, per port broadcast/multi-
high-rate, short-packet, continuous traffic that is deter- cast storm control, spanning tree protocol, and frame
ministic or highly time-critical. prioritization.

TCP/IP-based cluster communications between weigh- Minimize network load due to unwanted incoming IP
ing terminals is also time critical and must be ade- multicast traffic. Block IP multicast traffic generated
quately isolated from other network traffic. within the EtherNet/IP™ subnet from propagation into
the larger plant network.
Conversely, if a Ethernet TCP/IP-based production net-
work connected to a larger plant network, the continu- Sweating the little stuff. Heat ratings, electrical noise,
ous propagation of Multicast packets must be blocked. and grounding issues should be addressed with the
While the continuous information flow within the sub- appropriate solution.
net may be desirable for optimizing weighing, it can • Network cable connectors with IP67 environmental
cause a multicast message storm that degrades the ratings and extended temperature ratings to 80°C
plant’s overall network performance. are preferred when establishing industrial networks
• CAT6 or CAT6a industrial-grade shielded cabling
Optimizing industrial EtherNet/IP must be used in high noise environments
Rockwell Automation has provided the following rec- • In some cases grounded metal conduit can mini-
ommendations to optimize network performance when mize electrical interference.
using EtherNet/IP™. However, many of these recom- • Proper grounding can avoid loops that cause com-
mendations can also be applied to any Ethernet field- munication drops or signal interference.
bus to optimize I/O performance.
Don't reinvent the wheel. Use vendor-supplied
Select Unicast EtherNet/IP™ communication when- PLC sample code or other integration tools such as
ever possible. Unicast I/O for EtherNet/IP™ allows Rockwell Automation Add-on-Profiles (AOPs) and
for direct point-to-point communication between two Add-on-Instructions (AOIs) to simplify integrating
devices on a network. This communication is more devices into an automation network and minimize
efficient when I/O data does not need to be shared programming errors.
among multiple devices. Further information on

METTLER TOLEDO © 11/2016 - Data Connectivity 45

 METTER TOLEDO offers the user of Profibus and METTER TOLEDO also offers the users of CC-Link mod-
ProfiNet IO modules an example for Siemens Step 7. ules an Engineering Note which explains the configu-
Engineering notes explain the configuration to ensure ration to ensure a fast start and correct integration into
a fast start and correct integration. a Mitsubishi PLC.
Data Connectivity

5 Troubleshooting Communications

Data communication troubleshooting for a weighing analyzers, and cable performance analyzers are em-
terminal and automation system depends on the com- ployed when troubleshooting network media problems.
munication method being used. For serial or EtherNet
TCP/IP to PC, simple connection using a PC applica- For PLC based applications, some vendors supply
tion such as HyperTerminal can verify basic weight PC-based simulation software for viewing and verify-
data transfer via the terminal’s communication port. ing data communicated from a weighing terminal’s
PLC port. LEDs mounted to the communication PCB
Ethernet network troubleshooting is typically divided provide basic information regarding operating status.
into these areas: Bypassing the PLC application program and directly
• Network media (cabling, connectors, network writing to output command and data words can pro-
interface cards) vide powerful troubleshooting as well.
• Software settings/network configuration
• Network signal performance Weighing terminal troubleshooting can also occur via
remote access to a terminal’s configuration file, error
A variety of technician tools such as TDR (time do- logs, and web pages showing diagnostics or opera-
main reflectometer) devices, handheld network tional status.

METTLER TOLEDO IND560 weighing terminals

46 METTLER TOLEDO © 11/2016 - Data Connectivity

 6 Summary

Efficient transfer of process data to higher level MES or • Available budget

ERP systems along with intelligent weighing platform/ • Adverse operating conditions, such as high-pressure
Data Connectivity

system upgrades can: washdown, corrosive chemicals, extreme tempera-

• Enhance manufacturing process controls ture, electrical noise, and grounding
• Improve asset use • The data itself – who/what needs it, why, and in
• Lower operating costs what format?
• Generate measurable ROI • Is PLC connectivity is required, or will serial or
Ethernet connectivity work?
Clear goal identification – either performed internally,
or with the help of weighing process specialists – can Ethernet network troubleshooting requires knowledge
ensure that hardware and software investments reap of network media, configuration, and signal perfor-
intended process improvement dividends. mance. Some vendors supply PC-based simulation
software for verifying data communicated from a
Considerations for proposed system upgrades include: weighing terminal’s PLC port. Vendors themselves can
• Speed of process (for example, high-speed filling), help with comparisons of various weighing platform
which influences data exchange rates and system communication solutions.
• Existing equipment and potential connectivity

7 Additional Resources

More information on communication capabilities, data format, and fieldbus network-specific requirements for
METTLER TOLEDO weighing terminals are available via – www.mt.com/ind-process-data-integration.
• METTLER TOLEDO Terminals – www.mt.com/terminals
• ODVA DeviceNet™ Library – www.odva.org
• ODVA EtherNet/IP™ Library – www.odva.org
• Profibus/ProfiNet® – www.profibus.com
• Network Analyzer Wire Shark – www.wireshark.org
• Fluke Networks – www.flukenetworks.com
• Kepware/KepServerEX (OPC) – www.kepware.com
• www.mt.com/ind-encompass
• www.mt.com/ind-schneider-electric
• www.mt.com/ind-mitsubishi-plc
• www.mt.com/ind-siemens-plc

Mettler-Toledo GmbH
Industrial Division
www.mt.com/ind-food-guides
CH-8606 Nänikon, Switzerland For more information
Tel. + 41 44 944 22 11

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364129 / Marcom Industrial
47
 Greater Process Reliability
Process Reliability
with Intelligent Sensors

In the brewing industry, maintaining productivity and controlling operating costs is a

constant challenge. Maintenance demands for instrumentation and unplanned produc-
tion downtimes resulting from the failure of measurement technology are substantial
cost factors. Cutting-edge process analytical systems with built-in intelligence solve
this by predicting and indicating their own maintenance and reducing sensor lifecycle
costs, and also increase process reliability.

Introduction
Improving production efficiency is vital to successful
business operations. Part of that endeavor is ensuring
brewery equipment is operating correctly and is well
maintained. This is as true for analytical measure-
ment systems as it is for any other plant asset. Failure
to properly maintain measurement sensors can have
a significant impact on efficiency and production
costs. Reduced product quality, over- or underuse
of ingredients, or unplanned downtimes can easily
result from poorly calibrated or failed sensors. How-
ever, supporting an effective maintenance regime is a
time-consuming burden on skilled staff. The answer
is intelligent process analytical systems that not only
monitor themselves for wear and advise operators
when maintenance is required, but that also improve
process integrity.
Content
1 On-Board Intelligence
2 Digital Signal – Robust and Reliable
3 Plug and Measure – Fast and Simple
4 Predictive Diagnostics
5 Seamless Integration of Diagnostics Data
6 Asset Management
7 Conclusion
8 Additional Resources

48
 1 On-Board Intelligence nance management, which translates into increased
process reliability and reduced operating costs.

Intelligent Sensor Management (ISM®) is an innovative The basis of ISM is a microprocessor embedded in the
technology for analytical process parameters that sensor. Analog to digital conversion, memory storage,
Greater Process Reliability

combines many features into a unique solution: one and sophisticated diagnostics algorithms held on the
that is adaptable to specific production plant needs. integrated circuit allow a wide range of features and
ISM simplifies sensor handling and improves mainte- provide a wealth of system possibilities.

2 Digital Signal – the sensor signal causing uncertainty as to the accu-

racy of the measured value.
Robust and Reliable
ISM sensors operate differently. The on-board micro-
Traditional measurement systems send a sensitive an- processor converts the analog process value from the
alog signal to the transmitter which converts the signal measurement into a digital value and conveys this to
into a displayed measurement. Electrical interference the transmitter. Being digital, the signal is immune to
caused by surrounding equipment, the presence of interference from electrical fields and moisture, and re-
moisture in the air, and long cable runs can degrade mains stable even over extended cables.

3 Plug and Measure – propriately without any operator intervention (figure 1).
Now when an exchange of sensor is needed, this Plug
Fast and Simple Start Up and Measure functionality means a pre-calibrated sen-
sor can be installed
When replacement of an analog sensor is required, it and be ready to
may take a skilled operator up to one hour to configure measure in under a
and calibrate a new one. With ISM sensors, the cali- minute, therefore
bration data is retained on the internal microprocessor substantially reduc-
allowing the sensor to be calibrated away from the ing maintenance
process in a convenient location such as a laboratory time and allowing
or maintenance shop. Once calibrated, the sensor can instrument engi-
be stored until required. Further, when connected to an neers to concentrate
ISM transmitter, the pre-calibrated sensor is instantly on more skill-inten-
Fig. 1: Plug and Measure display on
recognized and the transmitter configures itself ap- sive tasks. M800 transmitter

4 Predictive Diagnostics – These tools allow a measurement point to be opti-

mized on an ongoing basis and for all critical situa-
Efficient Maintenance tions to be predicted so that maintenance staff can
respond before pro-
It has been estimated that as much as 60 % of main- duction is affected.
tenance conducted at breweries is not required. Main- Because measure-
tenance is often conducted on a scheduled basis, and ment point mainte-
an analytical sensor may get calibrated even though nance only happens
it may not actually be needed. ISM’s predictive diag- when it is required,
nostics have solved this. ISM sensors monitor them- you can be certain
selves for wear and stress based on past and current you are not wasting
process conditions. This information is converted into maintenance re-
tools such as the Dynamic Lifetime Indicator (DLI) and sources.
Fig. 2: M800 display showing DLI
Adaptive Calibration Timer (ACT) (figure 2). and ACT sensor diagnostics

METTLER TOLEDO © 11/2016 - Greater Process Reliability 49

 The Dynamic Lifetime Indicator (DLI) provides techni- emptively before they fail during operation, resulting in
cians with an indication of how much the exposure higher process reliability and fewer product quality
to the process has altered the integrity of consumable fluctuations.
sensor parts. In the case of METTLER TOLEDO carbon
dioxide and optical dissolved oxygen sensors, by The DLI and other
Greater Process Reliability

constantly analyzing the process conditions and other tools mean that a
factors, the DLI calculates the remaining reliable life- brewery’s mainte-
time of the sensors’ replaceable elements. The iMoni- nance strategy can
tor display on the M800 transmitter shows all sensor be changed from a
diagnostics using easily read traffic light color coding passive, costly and
(figure 3). unpredictable work-
flow, to a fully safe
Through observing the DLI, such sensor consumables and controlled pro- Fig. 3: iMonitor display on M800
with a short remaining lifetime can be replaced pre- cedure. transmitter

5 Seamless Integration
of Diagnostics Data
Integration of ISM sensor diagnostics into control ISM Diagnostics Tools
systems and asset management software allows Dynamic Lifetime Indicator (DLI)
real-time monitoring of sensor performance from the Using a unique algorithm, the Dy-
convenience of a maintenance room. This means DLI
Dynamic Lifetime Indicator
ACT
namic Lifetime Indicator continu-
Adaptive Calibration Timer

that if production staff are away from the process ously calculates the remaining
and a measurement point needs attention, it will be lifetime of sensor consumables.
TTM
noticed instantly. Time to Maintenance

Adaptive Calibration Timer (ACT)

Based on the above algorithm the
DLI
Dynamic Lifetime Indicator
ACT
Adaptive Calibration Timer
sensor predicts the time until the
6 Asset Management DLI
next calibration will be needed.
ACT
TTM
Time to Maintenance
Dynamic Lifetime Indicator Adaptive Calibration Timer

Time to Maintenance (TTM)

Optimizing the performance of analytical sensors en-
The sensor also indicates when
hances their reliability, improves process productivity, TTM
Time to Maintenance you will have to perform the next
and reduces operating costs. iSense software for ISM maintenance.
sensors offers accurate sensor verification and cali-
bration in any convenient location. The elec- CIP / SIP Counter
tronic user management logbook allows
Max. °C

CIP and SIP cycles are interpreted

00/NN Days of operation

control and tracking of all sensor activities

CIP
CIP/SIP Counter
MAX
with a proprietary, patented
Max. Temperature/ODI

ensuring complete documentation of ISM algorithm.

Max. °C

CAL
00/NN Days of operation

sensors over their whole lifetime. CIP

Calibration History
CIP/SIP Counter
MAX
Max. Temperature/ODI

Calibration History
Calibration history is stored in
CAL
Calibration History the sensor and can be used for
diagnostics.

Maximum Temperature /
Max. °C

Operating Days Indicator

00/NN Days of operation

CIP
CIP/SIP Counter
MAX
Max. Temperature/ODI
Information about the maximum
temperature the sensor has ever
CAL
Calibration History
been exposed to and the number
of operating days.
iSense software calibrating a dissolved oxygen sensor

50 METTLER TOLEDO © 11/2016 - Greater Process Reliability

 The DLI and other vital sensor data is also viewable
on iSense. Now you have a single point which re- Features overview of ISM sensors:
cords the condition of your installed sensor base. • More precise measurement signal compared
Asset management ensures you always have suffi- with analog sensors
cient stock of healthy sensors and allows you to en- • Advanced sensor diagnostics
Greater Process Reliability

hance maintenance planning. • Predictive maintenance functions

• Plug and Measure functionality
• Digital IP 68 connector
• CIP / SIP counter
7 Conclusion
Continuous improvement in process equipment effi- transmission, fast error-free sensor commissioning
ciency and maintenance are important business driv- and real-time diagnostics information combine to cre-
ers. In-line analytical measurement solutions that en- ate a powerful tool for improving process control and
hance process reliability and product quality, while maximizing process equipment availability.
simultaneously reducing operating costs, are going to
be of growing value. The flexibility offered by a wide range of solutions and
further planned developments guarantees ISM will re-
ISM’s numerous features and benefits mean that in- main at the forefront of process analytical measure-
creased measurement accuracy, reliability of signal ment technologies.

8 Additional Resources
Further information on ISM can be found on our website:
www.mt.com/ISM-brewery

ISM dissolved CO2 sensor ISM dissolved O2 sensor

Mettler-Toledo GmbH
Process Analytics
www.mt.com/ind-food-guides
For more information
Im Hackacker 15
CH-8902 Urdorf
Switzerland

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364127 / Marcom Industrial 51
 Package Quality Control
Quality Control
Net Content Control

Billions of packages of all kinds are filled around the world every day. “Package” can
mean bottle, jar, tube, box or can – any container filled with product. All prepackaged
goods by law display net weight or volume and number of pieces. Today, the value of a
product includes more than its assignment. Saleable elements include safety and image
as well. Even simple products include these elements and can influence their perceived
compliance with regulatory requirements and enhance consumer acceptance.

Thorough product inspection includes ensuring pack-

ages contain labeled amounts. Statistical Quality Con-
trol (SQC) can help. A quality assurance system based
on SQC provides, among other attributes the following
core quality data:
• Production (period) mean value
• Number of violations of the legally defined tolerance
limits T1- and T2-
• Mean standard deviation of the production (period)
• Other quality or safety relevant attributes (CCPs)*

A suitable control system must be fast, simple to op-

erate, reliable and objective and requires an up-front
investment. However, the right system can increase Contents
productivity and provide a return on investment within
1 Cost Control through Optimized Filling
12 months through:
• Minimized product giveaway caused by excessive 2 Available Methods
and continuous overfilling 3 System Considerations
• Prevention of government obstacles to 4 Summary
product distribution
• Better end-user product acceptance
5 Additional Resources
• Streamlined QA procedures/personnel
• Prevent legal conflicts

This paper addresses the aspects and benefits of

implementing robust quality data management so-
lutions and systems, such as METTLER TOLEDO’s
FreeWeigh.Net®, to ensure overall product quality
and safety improvement.

52
 1 Cost Control through Optimized Filling

Filling is subject to a large number of influences that general overfills can be costly and lower the revenue
can cause fluctuations in packaged goods weight. considerably. Even with the modest output rate of
Quality Control

However, weight fluctuations must not cause the net smaller companies, corresponding product give-away
weight of even a single package to fall appreciably be- costs are striking.
low stated net weight. Government regulations gen-er-
ally specify permissible underfill amounts. Accurate monitoring and quality data management
provides better results. Giving the process closely con-
Some manufacturers systematically overfill to elimi- trolled limits can help reduce expensive product give-
nate risk of consumer and legal complaints. But such away.

2 Available Methods – Random Sampling and 100% Inspection

In many countries static scales must be used to verify In-depth understanding of filling machine scatter and
compliance with net content legislation and produce package parameters are essential to select the right
package tare weight verification reports. Product spe- sampling method, random sampling on static scales
cific parameters and processes, in combination with or 100% checks of all packages using dynamic
financial and economic factors, usually dictate which Checkweighers.
method is beneficial on a production line.

Random sampling control 100% inspection control

with static scales with dynamic checkweighers
• Random sampling, • All packages are checked (100%)
• Rapid product change (size, weight) • Tolerance infringements are automatically
• Low space requirements sorted out
• Low system costs • Use in filling processes in which access to the
• Tare weights, component weighing and filling head product is difficult
control • Less control personnel
• Optimum regulation to the nominal fill quantity • Operator errors less probable
• Allows collecting and analyzing additional quality • Slightly higher deviations
and safety attributes
• Higher accuracy and repeatability

Process and economic factors to consider when choosing static or dynamic checkweighers include:
• weight fluctuation potential, filling machine repeatability/scatter
• product characteristics (package weight, package size, shape, …)
• production line throughput
• trade off between sampling speed and measurement precision
• initial investment budget
• running costs of ownership
• manual efficiency and personnel costs

SQC delivers good results SQC or 100% depending on speed 100% checks allow to sort out defects
and product

METTLER TOLEDO © 11/2016 - Quality Control 53

 How SQC helps The question of the optimum or lowest, possible fill
To truly quantify and control product fill, an under- quantity can be answered irrespective of the control
standing of Statistical Quality Control (SQC) is re- system used. The goal of the filling process is to attain
quired. SQC takes random sample data and creates optimum mean filling quantity while fulfilling net con-
comprehensive quality control information. tent legislation requirements.
Quality Control

This information helps ensuring that a batch meets

legal requirements.

Cost effectivness in the filling plant

Mean fill weight

Average fill quantity

Declared fill quantity
=
Tolerance limit T1-

Tolerance limit T2-

No packages allowed in this area

Consumer protection / legal requirements

SQC spot-checks determine batch acceptability

3 System Considerations

Ideally, a solution should address any needs for quali- Data connectivity
ty data acquisition throughout the factory and test labs. Industry standard data communication interfaces such
It should be highly configurable and expandable to en- as Ethernet with TCP/IP protocol, help keeping infra-
sure an enhanced degree of control with no need for structure costs low when adding and networking in-
software engineering during implementation or daily strumentation such as balances and scales, check-
routine. System design considerations include: weighers, metal detectors, terminals and sensors to a
comprehensive quality-control system, as well as oth-
System usability er existing devices to protect given infrastructure and
Intuitive user interfaces allow increased setup flexibility, limit investments.
ease of operation and more precise control during fill-
ing and packaging. Easy and fast data access
Easy and fast access to production parameters is cru-
cial. A key parameter in most cases is fill quantity.
However, increasingly other parameters such as for-
eign body detection, ingredient analysis data (e.g. pH,
moisture …), results from visual inspection or any re-
sults from other critical control points.

54 METTLER TOLEDO © 11/2016 - Quality Control

 Product Definition in the
specifications product catalog
Quality Control

Product selection
at the test site

Monitoring Sample/data
and report acquisition

Gaining quality information can be broken down to five easy steps with a well-designed solution.

Step 1: Product specification

Define declared net content, applicable tolerances, tare management and other quality attributes

Step 2: Catalog definition

Adding product data and test item information to define the quality process

Step 3: Product selection

Product is selected on the test scale or terminal in direct dialog with the system

Step 4: Sampling / data acquisition

Samples are taken, guided by the system according to test plan and quality process

Step 5: Monitoring and reporting

Results are automatically analyzed by the system and process deviations lead to immediate, alarm messages to
operators and supervisors.
Printed reports in addition to electronic records can be produced based on documentation requirements

Enhanced compliance
If the process begins deviating from the target, the The US FDA has implemented 21 CFR Part 11 in such
chosen solution should ensure that appropriate correc- a way that electronic audit documents become the
tive measures can be taken for enhanced compliance original, while paper printouts are non-binding copies.
as well as optimized production. For compliance track- Companies wishing to comply with 21 CFR Part 11
ing, traceability of all quality and safety relevant data must therefore implement systems that support it.
is critical over the entire life of ingredients as well as
final products. Overall, a well-implemented quality data management
solution or system reduces user error and subsequent
Increasing regulatory requirements require food indus- loss of product information. The resulting improved
tries such as infant formula or nutraceuticals to adapt product quality helps a manufacturer reach important
the longer the more to Pharma like practices such as operating targets.
‘audit trail’ or electronic record keeping.

METTLER TOLEDO © 11/2016 - Quality Control 55

 4 Summary
Overfill cost is directly related to raw material costs. Various solutions are available, such as static scales
But safe-margin overfills are an effective way to en- for offline random sampling, as stand-alone or
Quality Control

sure compliance with net content legislation. network solutions of net content data or inline check-
Overfills are costly, even with the modest output rate weighers for 100 % data checks.
of small companies. Calculated, minimized overfilling
can be very effective at controlling giveaway and its
resulting expense without increasing personnel costs.

Package quality Product quality

parameters parameters
Sealing ok? Sensory test
Label ok? Visual appearance (colour …)
Undamaged? Single piece weight
Net content ok? Viscosity
Texture i.e. particles size
Expiry date ok?
Moisture
Batch/lot ID ok?
pH-value
Metal free?

Typical FreeWeigh.Net ® screens

Product quality – a function of countless individual variables and attributes can be processed with FreeWeigh.Net ®

A state of the art quality data management system, at individual workstations can account for unique
such as METTLER TOLEDO’s FreeWeigh.Net® offers company structure and expansion. It also integrates
multiple benefits to food manufacturers. It allows data easily with MES or ERP systems.
collection for important quality attributes from static
scales, in-line Checkweighers, Foreign Body Detectors, An integrated quality data management system is an
pH meters, sensory test panels. It alerts operators to excellent way to achieve better quality control and real
required adjustments almost immediately, thus helps cost-savings. METTLER TOLEDO offers solutions and
preventing failed production batches. Further, central- systems that pay for themselves and provide a full ROI
ized test planning and decentralized data acquisition within 12 months or less.

56 METTLER TOLEDO © 11/2016 - Quality Control

 5 Additional Resources
• WELMEC (European Cooperation in Legal Metrology)
www.welmec.org
Quality Control

Additional information on METTLER TOLEDO solutions can be found under the following links:

• General SQC information

www.mt.com/sqc

• SQC Application Overview

www.mt.com/sqc-application

• Quality data management solution FreeWeigh.Net®

www.mt.com/freeweighnet

• Request your free copy of the comprehensive SQC guide

www.mt.com/sqc-guide

• Asses your potential savings through reduction of overfilling – ROI Calculator

www.mt.com/sqc-calculator

Mettler-Toledo GmbH
Industrial Division
www.mt.com/ind-food-guides
CH-8606 Nänikon, Switzerland For more information
Tel. + 41 44 944 22 11

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364114 / Marcom Industrial
57
 In-line Checkweighing
In-line Checkweighing
Aspects of a Key Technology

A checkweigher is usually part of a typical quality control system, ensuring that every
product leaving a production line is the right weight and corresponds to packaging re-
quirements. Selling products with incorrect weights causes problems for manufacturers:
underweight products can result in companies being fined, whilst overweight products
generate expensive product giveaway.

Checkweighers systematically weigh 100 per cent of

production line items and provide a complete overview
of data such as:
• Product counts
• Batch tracking
• Total weights
• Good weights
• Rejected weights

In an increasingly competitive marketplace, check-

weighers are essential in fulfilling ever-changing
customer needs and in complying with local Weights
& Measures standards, as well as global standards.

Different checkweighing approaches and implemen-

tation considerations are discussed in this paper.
Contents
1 Benefits of Checkweighing
2 Checkweigher Uses/Statistical Uses
3 Production Phases where Checkweighers
Are Used
4 Static and Dynamic Checkweighers
5 Integrated or Combination Systems
6 Summary
7 Additional Resources

58
 1 Benefits of Checkweighing

As part of overall quality control, checkweighing pro- manually can now be collected in a fraction of the time
tects both manufacturer and consumer. Manufacturers by a checkweigher, resulting in the following benefits.
In-line Checkweighing

are assured that they use raw materials effectively and

offer compliant products. Their brand and reputation is Improved resource use
protected. Consumers receive a high quality product An accurate checkweigher makes the most of existing
that includes the correct net content or parts. resources though tighter production tolerances. More
items can be created using the same amount of raw
Today’s technology makes checkweighers more reli- materials. Figure 1 shows a simple calculation to un-
able and accurate than ever before. The information derline the savings which can be made by reducing
that a quality team would have previously collected overfill by just 1 gram.

Package and production information Savings (1 gram overfill reduction)

Labelled package weight = 450 grams 0.1 ct savings per package
Material cost = 0.1 ct per gram 20 ct savings per minute
Line rate = 200ppm €12 savings per hour
Line utilization = 65% €124 savings per day
Shift = 8 hours €28,704 savings per year
Shifts per day = 2
Production days per year = 230
The reduction of 1 gram overfill as shown in this example would free enough raw materials to produce an additional 60,000 products

Figure1: Example Showing the Impact of Reducing Overfill by 1 gram

Enhanced product consistency

A line with a throughput of 100 packages per minute
where 15 packages are manually sampled every hour
means only 0.25 percent of total packages are sam-
pled. A checkweigher however automatically weighs
100 percent of all packages on the line. Operators can
react immediately if a problem is detected to ensure
results are more uniform.

Increased overall equipment

effectiveness (OEE)
Checkweighers provide real-time monitoring of pro-
duction processes, including yield statistics and SPC
Figure 2: Real-Time Monitoring of Production Processes
trending all of which can be used for process improve-
ments and operating efficiencies (Figure 2). This can
result in increased OEE. Better net content
Net content laws and regulations differ from country to
Filler monitoring country. However, an effective checkweigher program
Active monitoring of filler performance minimizes over can minimize risk of non-conformance and eliminate
and underfills by keeping filler heads properly adjust- potential lawsuits and customer complaints.
ed. Checkweighers communicate directly with the filler
control/network and existing factory automation for
seamless feedback control.

METTLER TOLEDO © 11/2016 - In-line Checkweighing 59

 Fewer false rejects, less rework Brand/legal protection
and reduced scrap Branding frequently drives repeat purchases and justi-
An accurate, well-maintained checkweigher improves fies premium product pricing for manufacturers and
processes while reducing scrap and reworks. False re- retailers. If a company is investigated after consumer
complaints, checkweigher documentation will provide
In-line Checkweighing

jects are also minimized. Accuracy becomes more

precise as zone settings are refined. invaluable evidence of appropriate quality control.

2 Checkweigher Application/Statistical Application

Checkweighers perform a critical range of quality con- • Weight zone or classification analysis
trol functions based on weight. • Monitoring efficiency through total count
and total weight
Manufacturers use checkweighers to:
• Check for under and overweight
• Check volume or density (bread, yogurt)
• Ensure net content for pre-packaged goods
• Measure raw/unwrapped food prior to packaging
• check for missing components
(labels, instructions, lids, leaflets)
• Verify counts for warehouse or delivery
• Check mixes for solid-to-liquid ratio
• Reduce giveaway through filler adjustments
• Classify products for grading or portioning ensure
customer or agency (USDA, FDA, OIML, FPVO) Figure 3: Monitoring production data
standards are met
• Report production line data to drive process im- • Providing SPC for closed loop control and automatic
provement process adjustments
• Interfacing with business systems, Programmable
Statistical uses include: Logic Controllers (PLC) and SCADA systems that
• Monitoring speed efficiency (packages per minute) link the checkweigher to the production process,
• Monitoring standard deviation for out of tolerance including checkweigher remote control
conditions or trends
• Keeping and management of regulatory records All of these uses add up to increased quality control
• Analyzing filler head performance and its resultant production line and compliance
• Accumulating totals for a day, shift, hour, batch or run improvements. It may even lead to reductions in
• Providing Statistical Process Control (SPC) charts for quality control personnel.
manual process adjustments

3 Production Phases where Checkweighers Are Used

Figure 4 shows four distinct areas where checkweigh- a signal to the divider/former to maintain consisten-
ers are typically used in a manufacturing operation. cy and reduce giveaway.
These include:
• Primary packaging – to checkweigh tubes of
• Prior to packaging – such as handling raw dough frosting prior to cartoning to keep fillers tuned and
prior to freezing. The checkweigher could also send prevent non-conforming product from reaching

60 METTLER TOLEDO © 11/2016 - In-line Checkweighing

 the next process stage. This eliminates rework • After case packing – specialized checkweighers
and costly waste in the secondary production called caseweighers ensure short cases are not
phase. shipped. They may also transmit case weight data
to a manifesting system for shipping. This check-
• Secondary packaging – ensure all components weigher is also used for large bulk product bags
In-line Checkweighing

have been included in the final package. such as 25kg bags of dry dog food or flour for net
weight control.

Figure 4: Checkweigher usage in manufacturing operations

4 Static and Dynamic Checkweighers

In many countries static scales must be used to usually dictate which system is used on a
sample product for completion of net contents and production line.
package tare weight verification reports. Processes,
in combination with financial and economic factors, A comparison of static and dynamic checkweighers
follows.

Static checkweigher Dynamic checkweigher

• Weighs stationary objects • All packages are checked (100%)
• Requires manual intervention • Tolerance infringements are aretomatically sorted out
• Sample spot-checking • Use in filling processes in which access to the product
• Target weights/sample tests is difficult
• Higher accuracy/repeatability •100% process control
• Slightly higher deviations

Process and economic factors to consider when • Production line throughput

choosing static or dynamic checkweighers include: • Trade off between sampling speed and
• Initial investment budget measurement precision
• Weight fluctuation potential, filling machine repeat- • Initial investment budget
ability/scatter • Running costs
• Product characteristics (package weight, package • Manual efficiency and personnel costs
size, shape, ...) • Governance of sample rates

METTLER TOLEDO © 11/2016 - In-line Checkweighing 61

 5 Integrated or Combination Systems
Integration of other inspection devices such as metal Primary benefits of combining devices include:
detectors, X-ray devices, cameras, scanners, marking • Consolidation of user interfaces
In-line Checkweighing

systems or sensors makes the checkweigher part of • Reduced for set-up and line changeover time
a high performance product inspection solution. • Less opportunity for operator error; shorter training
• Reduction in maintenance and cleaning costs
Integrated systems make it easy to check for a wider • Smaller equipment footprint; maximized production
variety of quality control items, such as: space
• Open flaps, missing caps
• Package orientation and skew detection Using a combination system, rejected products
• Printed information such as batch number, expira- can be quarantined at once for effective management
tion date of non-conforming products.
• Bar code labels and RFID tags
• Contaminants such as metal, stone or glass Integrated systems are easier to install and usually
less expensive than separate systems.

Checkweigher combination systems with x-ray or metal detector

6 Summary

Today’s technology makes checkweighers more reli- • Less product giveaway

able and accurate. Information previously collected • Enhanced consistency and operational effectiveness
manually can now be collected in a fraction of the • Better net content
time, resulting in: • Reduced scrap
• Improved quality control • Brand/consumer protection
• Better raw materials use rates

62 METTLER TOLEDO © 11/2016 - In-line Checkweighing

 Checkweighers are used to: Both static and dynamic checkweighers have places
• Check under- and overweight, volume and density on production lines. Decisions about how to imple-
• Ensure net content ment each must be made based on application and
• Check for missing components budget.
• Verify counts
In-line Checkweighing

• Classify products for grading or portioning Integration of other devices such as cameras, scan-
• Ensure customer or agency standards are met ners, metal detectors and X-ray systems add up to
• Report production line data to drive process a high performance inspection solution, providing
improvement benefits such as a smaller warehouse footprint and
reduced maintenance costs.

7 Additional Resources

• METTLER TOLEDO Garvens Principles of Checkweighing Guide serves as a definitive checkweighing reference
work with helpful information on everything from basic principles to comprehensive program implementation.
Request your free copy at
www.mt.com/cwguide

• White Paper – Overall Equipment Effectiveness (OEE)

Increasing the productivity of a production line is not just a matter of buying faster equipment. Using the OEE
(Overall Equipment Effectiveness) calculation, companies can become more efficient and utilize their process-
es more effectively. This white paper describes OEE in detail and shows, using the simple calculation, how you
can improve productivity whilst also reducing costs.
www.mt.com/Garvens-OEE

• METTLER TOLEDO On-demand webinars allow 24/7 self-paced learning on a wide range of important process
integration topics
www.mt.com/pi-ondemand

• OIML – International Organization of Legal Metrology OIML R87 Quantity of product in prepackages
www.oiml.org/publications/R/R087-e04.pdf

• NIST – US National Institute of Standards and Technology, Handbook 133, Fourth Edition
http://ts.nist.gov/WeightsAndMeasures/upload/Complete-HB133-05-Z-2.doc

Mettler-Toledo GmbH
CH-8606 Greifensee, Switzerland
www.mt.com/ind-food-guides
Tel: +41-44-944 22 11 For more information

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364115 / Marcom Industrial

63
 Vision Inspection
Vision Inspection
Driving Quality and Process Security

Vision inspection provides highly specialized and effective quality control.

It brings together cameras, lights and image processing software in a unified
system which inspects high speed manufactured packaging and labels.

Vision systems help to prevent distribution of defective

products and significantly enhance a manufacturer’s
quality assurance. This reduces the risk of a product
recall and its associated costs by preventing the distri-
bution of mislabeled or poor-quality packaging to con-
sumers. They can even lower personnel costs because
fewer employees are required for quality control.

Unlike a human inspector, vision systems never blink.

This ensures that every product on the line is inspected
for defects.

This paper seeks to support vision inspection imple-

mentation by exploring uses, benefits and system
Contents
design considerations that assure optimum function
at high line speeds. 1 Why Vision Inspection?
2 Introduction to Machine Vision
3 Uses of Vision Inspection
4 Reasons for Establishing Vision Inspection
5 Designing for Reliability
6 Summary
7 Additional Resources

64
 1 Why Vision Inspection?

Vision inspection helps to prevent defective product

from being distributed – a very valuable function for
Vision Inspection

manufacturing, assembly and packaging operations.

Research shows that 65 percent of consumers refer to

packaging when buying products. If a package's label
is missing, incorrect or damaged, a customer may be
exposed to an allergen or harmful ingredient unknow-
ingly. This exposes the manufacturer to a potential
lawsuit on top of the cost of a product recall and po-
tential lost business. The Canadian Supplier “Packag-
ingWorld.com” confirms that 55 percent of food indus-
try recalls arise from improper labeling.

In an effort to reduce these label-based product recalls, ability to inspect every product on the line, vision
manufacturers are turning to vision systems. With the ensures defective products never reach customers.

2 Introduction to Machine Vision Systems

Machine vision brings together cameras, lighting and ing devices feature the latest in frame-grabbers, soft-
image processing software to create a system that ware, and sensor technology.
“sees” objects, accurately inspecting them for flaws
at high speeds. The vision software is the brain of the Machine vision systems cost-effectively:
system, processing the camera images and comparing • Conduct item inspections
them to stored images of how products should look. • Verify accuracy of work-in-process assembly
• Maintain “e-pedigree” records tracking a product
Machine vision has become more sophisticated and through the production and packaging life. This
user-friendly since its introduction in the 1980s. Initially, helps demonstrate due diligence as well as maintain
optical character recognition (OCR) systems were used package quality.
in industrial applications to read and verify letters, sym-
bols, and numbers. Today’s higher-level image captur-

Light source –
Camera – “Eye of illuminates product
System” – captures being inspected
inspection image
used by system

Product being
inspected
PC – supporting the
HMI, and software

METTLER TOLEDO © 11/2016 - Vision Inspection 65

 3 Uses of Vision Inspection
By inspecting products and packages at production • Identify products /pallets – alpha/numeric & bar
line speeds, a machine vision system can instantly codes are verified; item placement is ensured and
Vision Inspection

identify: pallets are identified as correct before shipment

• Damaged or malformed products and packages • Confirm parts – coding verification helps ensure
• Misapplied elements such as crooked caps or proper assembly
incorrect labeling • Update inventory & maintenance data –
• Missing parts or kit components communicating with an enterprise system to update
production, inventory and maintenance data; if de-
Such a system can simultaneously check a bottled fects exceed threshold, the line can be shut down for
liquid product for a misapplied cap, proper neck shape, adjustments
foreign material, fill level, and the presence or posi- • Facilitate automatic changeovers – automatically
tioning of the label. The right system will also track adjusting camera position and conveyor speed after
rejects so management can use the information to viewing a new package or programmed puck.
further improve processes.
Of course, the level of automation depends on cus-
A vision system can easily: tomer needs and budget. Competing systems offer
• Reject defective items – some systems even sepa- various feature combinations. METTLER TOLEDO
rate defective packaging to be recycled from con- CI-Vision, for example, can include all of the features
taminated packaging to be scrapped described above and more.

4 Reasons to Establish a Vision Inspection Program

It is important to identify why the program is being selecting a vision system with flexibility in its design
considered. ROI for a well-designed vision inspection a better long-term investment.
program is achieved through:
• Minimized quality defects Quality assurance
• Enhanced customer/consumer protection Quality problems can cause output loss – particularly
• Protection of company brand and reputation on high-volume automated lines. Such costs can be
• Easier adherence to best practice guidelines and easily overshadowed when customers or consumers
industry standards discover defective product, which can result in product
• Minimized risk and of product recalls and returns recall, damage to the brand, adverse publicity, and
• Staff reductions potential legal action.
• Lowered costs resulting from the above
A thorough vision inspection program reduces internal
When a vision inspection program has been optimized waste, improves output, and all but eliminates cus-
for a manufacturer’s desired inspection capabilities, tomer complaints. This inevitably yields a better return
benefits and cost savings continue year after year. than money lost to additional raw materials, line
Changes to a product's packaging shape or design downtime, consumer response tactics, and lawsuits.
can render a less-flexible system design obsolete, Higher profitability is the result.
which can have a negative impact on ROI. This makes

66 METTLER TOLEDO © 11/2016 - Vision Inspection

 Customer/consumer protection While no legal requirement for vision systems exists,
Modern manufacturing techniques are constantly im- the records and statistics produced by a vision system
proving to eliminate quality defects, although there is can provide evidence of due diligence in the event of a
always a risk that the processes or procedures can product recall or lawsuit. Additionally, recent legis-
break down. Manufacturers have an obligation to min- lation in the United States has placed an even greater
Vision Inspection

imize these instances and ensure consistent quality emphasis on the product labeling process, making
and end-user safety. Vision inspection can protect vision inspection a more attractive proposition.
retailer relations and future business opportunities.
Minimizing risk of product recalls/returns
Brand/reputation protection The consequences of a defective product reaching the
Strong product branding gives retailers and consum- marketplace continue to increase. Consumers may
ers assurance of safety and quality, drives repeat pur- take legal action or contact media. In order to protect
chases and justifies premium product pricing. For this themselves, retailers will often fine manufacturers who
reason, a manufacturer must protect the brand and deliver defective products. This adds to the difficulty of
company reputation. Documentation provided via a getting fairly priced product on store shelves. The
vision inspection system can provide evidence of a overall result can be devastating to a manufacturer's
sufficient protection program. bottom line.

Adherence to best practices/ An effectively managed vision inspection program

can help keep defective product from reaching retail-
industry standards
ers. It can inspect one hundred percent of products
Vision inspection systems frequently become the focus
coming down a production line at real time, lowering
of audits, especially if they are used as a CCP in a
risk of product recalls, returns, and fines.
HACCP program. They provide evidence of a factory-
wide quality program and can help with:
• Internal food safety and management system audits
• Retailer audits
• Quality management system audits e.g.
ISO9001:2000
• HACCP audits, including BRC, IFS, SQF 2000, and
ISO 22000

METTLER TOLEDO © 11/2016 - Vision Inspection 67

 5 Designing for Reliability

External factors influence reliability in predictable ways. Inspection speed

Accommodations for these external factors must be While conveyor speed is seldom a factor when dis-
Vision Inspection

considered to ensure: cussing system reliability, the processing power of the

• statistical repeatability – detecting the same defect vision system is often the critical factor which will de-
on the same bottle sent through the system multiple termine how quickly inspections can happen. The
times to consistently detect defects at production more powerful the processor, the faster the inspection
speed; and system can perform.
• measurement repeatability – ensuring measure-
ment differential on a single part measured multiple Lighting
times is no greater than a small fraction of tolerance. Optimum set-up requires experimentation so inspected
features present with maximum contrast. Good set-up
When comparing solutions, ensure that repeatability increases performance and decreases software com-
is being measured the same way. In-line simulations plexity. Possibilities include:
make sure that inspections are repeatable for the in- • Diffuse darkfield, axis, and backlight methods
tended application and operating environment. Factors • Fluorescence, infrared or ultraviolet light
that influence repeatability and reliability include the • Spectrum verification for color
following. • Polarization to increase contrast between direct and
diffuse reflection
Mechanical design
As the camera’s lenses, standoff distances and light Multiple illumination set-ups or camera stations might
sources are determined, mechanical setups including be required to avoid interference among inspections.
camera and light mounts must be considered. Devices Different colored lights in combination with colored
must be protected against vibration or shock; isolation camera filters may be another alternative.
might be necessary.
Product handling
Cameras and light positions should be adjustable Product must display in a consistent manner. A well-
independent of each other and include appropriate designed solution can handle a certain amount of
lock-down. variation in product presentation through software or
special optics.
Environmental conditions
Plant vibration, dust, ambient lighting, humidity, and
temperature changes can become acute when running
multiple inspections at high speeds. Consider equip-
ment in factory conditions to avoid undesirable line
speed reductions in production.

68 METTLER TOLEDO © 11/2016 - Vision Inspection

 6 Summary

Vision inspection can be a critical element in a system ROI is achieved through:

that prevents distribution of defective product and • Enhanced customer/consumer/brand protection
Vision Inspection

can significantly enhance quality assurance. Vision • Best practice and industry standard adherence
inspection systems never blink, detecting virtually • Fewer product recalls/returns
100 percent of the defects they are programmed to • Reduced personnel
capture, helping to ensure defective and mislabeled • Lowered costs
products never reach consumers.
Mechanical design, environmental conditions, inspec-
Machine vision cost-effectively identifies: tion speed, lighting and product handling must be
• Damaged or malformed products and packages considered in the system design phase or when com-
• Crooked caps or labeling paring different solutions. Thus, different solutions are
• Correct pallets/parts best considered in their operating environment.
• Inventory automatic line changeovers
When a vision inspection program has been optimized
for a manufacturer’s desired inspection capabilities,
benefits continue year after year.

7 Additional Resources

• METTLER TOLEDO CI-Vision “Building an Effective • METTLER TOLEDO On-demand webinars allow 24/7
Vision Inspection Program” Guide serves as a defini- self-paced learning on a wide range of important
tive reference work and provides detailed insight into process integration topics
specifying and installing the right vision inspection www.mt.com/pi-ondemand
solution. Request your free copy at
www.mt.com/ci-vision

Mettler-Toledo GmbH
CH-8606 Greifensee, Switzerland
www.mt.com/ind-food-guides
Tel: +41-44-944 22 11 For more information

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364118 / Marcom Industrial

69
 Foreign Body Detection
Metal Detection
Metal

In order to make informed decisions about metal detection systems, it is important

to gain an understanding of the main system components and principles of operation.
This chapter aims to deliver a basic overview and develop an understanding of metal
detection technology, equipment capabilities and performance.

A metal detection system can represent a significant

capital investment. Equipment must be designed for
the intended application and used in an effective man-
ner to ensure ROI. A solid metal detection program can
reduce incidents of broken machinery and resulting
output loss when metal items are discovered before
processing. Perhaps more importantly, a metal detec-
tion program can reduce litigation risk and mone-
tary / brand image costs when metal contaminated
products are discovered after delivery.

A well-designed metal detection program must focus

on good manufacturing practices, correct equipment
selection, proper installation and consideration of
equipment in a broader foreign body/metal detection
program.

This paper will seek to support implementation of an Contents

effective program by exploring: 1 The Case for Metal Detection
• Reasoning for metal detection 2 Metal Contamination Sources
• Metal contamination sources
3 Production Stages where Metal Detection
• System components
• Often-overlooked system design considerations
Is Used
• Additional resources on detection and governing 4 System Components
standards 5 Key Design Elements
6 Summary
7 Additional Resources

70
 1 The Case for Metal Detection

Reasons for implementing a professional metal detec- No broad-based legal requirement for metal detection
tion program include the ability to: yet exists, though different global HACCP based food
Metal Detection

• Minimize costs safety standards put the burden of establishing reliable

• Increase manufacturing uptime product inspection programs on manufacturers to mi-
• Enhance consumer protection nimise the risk of foreign body contamination within
• Maintain brand/company reputation the finished product. In legal proceedings, metal de-
• Meet certification and compliance standards tection systems help manufacturers prove due dili-
• Demonstrate due diligence gence. Major retailers may also instate their own
codes of practice. Increasingly, formal metal detection
A metal detection program based on effectively de- is expected before supplier approval is granted.
signed and installed technology is critical. It can help
a manufacturer avoid costly contamination errors Metal detection has also become important in safety,
that damage machinery and cause loss of output customer, quality, and regulatory audits such as FSSC
in-process or result in a product recall, adverse pub- 22000 and SQF1000/2000 Code, as well as FDA,
licity, and legal action after shipment. USDA, IFS and BRC national/international certification
standards. Links to more on these standards can be
found in this paper’s Additional resources.

2 Metal Contamination Sources

Contamination sources include: Good working practices help keep these metal parti-
• raw materials – lead shot in meat, wire in wheat, cles from entering production flow. However, correct
tractor parts in vegetables, hooks in fish metal detection
• personal effects – buttons, pens, jewelry, coins, equipment selection
keys, hair/paper clips and integration maxi-
• mechanical maintenance – screwdrivers, welding mizes product rejec-
slag/copper wire/metal shavings following repairs tion once metal has
• plant processing – crusher, mixer, blender, slicer entered the produc-
and transport system parts including screens, mill- tion stream.
ing slivers and foil

3 Production Stages where Metal Detection Is Used

Metal detectors are primarily used at two production Finished Product Inspection, which eliminates con-
stages. These are: sumer danger and ensures compliance with retailer
and consumer brand quality standards.
Bulk “In-Process” Inspection, which eliminates metal
before bulk items are broken down to protect machin- A combination of inspection types often provides the
ery (grains/meat before milling/grinding) and reduce best results.
product/packaging waste by eliminating the need to
reject finished product.

METTLER TOLEDO © 11/2016 - Metal Detection 71

 4 System Components

A typical system consists of four main parts. plastic chutes mounted on an incline or non-metallic
pipes mounted horizontally or vertically to inspect
Metal Detection

Detector coil/search head powders or liquids.

The first type of metal detector utilizes a ‘balanced coil’
search head. Detectors of this design are capable of Automatic rejection system
detecting all metal contaminant types, including fer- An automatic reject device is often fitted to the trans-
rous, non-ferrous and stainless steels, in fresh and fro- port system to remove contaminated product without
zen products. The products being inspected can be ei- manual intervention. Styles include air blast, push
ther unwrapped or wrapped, and can include products arm, or drop flap. Reject device type depends on the
wrapped in metallised films. inspected product.

The second detector type utilises permanent magnets Other components

in a ‘Ferrous-In-Foil’ search head. These search heads To enhance total system capacity and support due
are capable of detecting ferrous metals and magnetic diligence extra fail safe and monitoring systems are
stainless steels only within fresh or frozen products now widely available and may include:
which are packed in an aluminium foil wrapping. • A rejected product collector/container
• A cover between detector and reject device
User interface/control panel • A failsafe alarm to signal faulty operation
The front-end of the control system, the user interface • A sensor to confirm contaminated product is rejected
is often mounted on the search head. It can also be • A beacon and/or alarm to signal scheduled tests or
remote and connected with cables if the search head full reject bins
is too small or installed in an inaccessible location. • Reject container secure/locked monitor
• Air failure alarm
Transport system • Keyless reject container locking facility
The transport system passes product through the ap-
erture. Conveyors are common. Alternatives include

5 Key Design Elements

Reliability is critical. It helps avoid difficult choices tures. However, these “add-ons” will not necessarily
such as stopping production when the metal detection contribute to detector effectiveness. A long feature
system is down or continuing to operate with contami- checklist and an assumption that the brand with the
nation risk. Despite widespread metal detector use, longest list is the best choice can prove a costly error.
few guidelines are available to help users evaluate de- “Which unit is more sensitive?” as a basis of compari-
tector reliability. son also does not provide a full picture, as this is only
one of several important factors in a detector’s function.
Factors that help ensure a system’s success include
ease of set-up, mitigation of drift/erratic detection, and Factors that influence reliability include:
elimination of false rejects without constant attention • Stability
to maintain sensitivity standards. Ensuring actual, ef- • Electronic drift
fective “production line” sensitivity means taking the • Repeatability
following critical elements into account. • Ease of set-up
• Radio frequency immunity (RFI)
Overall detector design • Modular electronics design
Modern metal detectors benefit from advanced micro- • Self-checking/condition monitoring
processor technology, adding a range of appealing fea- • Fail safe operation

72 METTLER TOLEDO © 11/2016 - Metal Detection

 Metal detector selection should also meet a product’s Good conveyor design can avoid loops that create
hygiene requirements and operating environment. If static build up and interference. Fully welded structures
the product is high-risk, such as meat or dairy, the with appropriate metal-free zones, isolated rollers, pul-
metal detector should be constructed to withstand leys, cross structures and detector head mountings are
deep cleaning and sterilization to avoid expensive re- essential. Belts should be metal-free and manufac-
Metal Detection

pairs resulting from water/steam ingress. tured with contaminant-free joints. Anti-static materials
should be avoided.
If a metal detection system is to be used in a potential-
ly explosive environment such as a flour mill, system If these precautions are not taken, false rejects gradu-
design should be certified and the manufacturer ap- ally increase. The easy solution is to downgrade
proved to sell such systems. equipment sensitivity. However, this can result in con-
travention of sensitivity standards and poor perfor-
A more in-depth look at other performance consider- mance.
ations follows.
Non-conveyor design
Balance stability/vibration immunity Similar considerations should be given to metal detec-
The majority of metal detectors in use today are bal- tion systems that do not incorporate conveyors such
anced coil, so mechanical stability affects perfor- as vertical pipelines for liquids and slurries. Poorly de-
mance. Very small movements, such as temperature signed supports and reject devices reduce metal de-
expansion, mechanical shock, or external vibrations tection program effectiveness.
can cause false triggers or balance drift.
Reject mechanism design
Systems that have to be manually balanced on a regu- Reject systems are probably the weakest part of most
lar basis or that are prone to vibration are of little value detection systems. As a result, contaminated products
on an automated production line. Good electronics de- are not reliably rejected. A correctly specified system
sign such as automatic balance control and good me- should reject all contaminated product under all cir-
chanical design such as enhanced potting techniques cumstances independent of contamination frequency
help minimize system failures. or where metal is found within the product.

Conveyor design Hygienics & safety

Metal detectors emit a high frequency signal that cre- Metal detection systems must account for the op-
ate tiny eddy currents. These currents have no effect if erating environment and appropriate sterilization.
they remain constant. However, if the conveyor has in- Good design:
termittent jolts of variable resistance, currents change • Eliminates cavities/bacterial traps
and create interference in the form of eddy current • Seals hollow sections
loops. • Avoids ledges and horizontal surfaces
• Uses open-design, continuous-weld frames for easy
Metal-to-metal contact points are primary loop sourc- access and cleaning
es. These include: • Allows hygienic electrical cable, trunking and pneu-
• Bolted assembly supports matic service management
• Pulley shafts and bearings
• Chain drives and guards System design should also meet statutory regulations
• Reject supports and standards in force at the time of sale. For exam-
• Metal conduit clamps ple, CE markings in machinery standards minimize
employee injury risk, which also reduces costly work-
Joint oxidation or changes in lubrication can cause ers’ compensation claims.
eddy currents to worsen.

METTLER TOLEDO © 11/2016 - Metal Detection 73

 Failsafe system design Reject confirmation can show when contaminated
What happens if a reject device does not remove product reached the reject bin; built-in condition
contaminated product or a fault occurs within the monitoring can provide early warning of operational
detector? Failsafe features mitigate malfunction risks. state changes.
Metal Detection

6 Summary

A metal detection system that is capable of consistent, shot, wire, machine parts, personal effects, slivers,
reliable detection without false rejection will win the shavings and foil. Attention to conveyor and reject sys-
confidence of line operators and management. tem design also helps ensure effective operation by
eliminating signal eddy loops that create interference,
Effectively designed and installed technology is key. increase false rejects and decrease sensitivity.
With it, a manufacturer can avoid costly contamination
errors that damage machinery and cause reduced out- No broad-based requirement for metal detection exists
put during processing – or worse, loss of reputation, yet. Though to help minimize risk of contamination in
product recall, adverse publicity, and legal action after the finished product, different global HACCP-based
shipment. food safety standards such as IFS and BRC put the
burden of establishing reliable product inspection pro-
Attention to design before purchase and during instal- gram onto food manufacturers. Metal detection sys-
lation will ensure ROI. This includes a review of bal- tems can help manufacturers prove due diligence and
ance stability to avoid drift so a system can reliably also become important in internal safety, customer,
detect potentially damaging objects such as metal quality, and regulatory audits.

74 METTLER TOLEDO © 11/2016 - Metal Detection

 7 Additional Resources
• METTLER TOLEDO Safeline Metal Detection Guide serves as a definitive reference work on building
a cost-effective metal detection program, improving overall production productivity and protecting
Metal Detection

your brand. Request your free copy at

www.mt.com/metaldetection

• METTLER TOLEDO On-demand webinars allow 24/7 self-paced learning on a wide range of important
process integration topics
www.mt.com/pi-ondemand

Standards increasingly call for food/allied product inspection via metal detection. These resources also offer
additional information on food inspection using metal detection equipment:

• British Retail Consortium (BRC)

www.brcglobalstandards.com

• CIES – International Committee of Food Retail Chains

www.ciesnet.com

• Codex Alimentarius
www.codexalimentarius.net

• Food and Agriculture Organisation (FAO) of the United Nations

www.fao.org

• International Food Standard (IFS)

www.food-care.info

• ISO 22000:2005 – Food Safety Management System Standard

www.lrqa.co.uk/certification/food/iso22000/

• Safe Quality Food (SQF) Institute

www.SQFI.com

• United States Department of Agriculture (USDA)

www.usda.gov/wps/portal/usdahome

• United States Food and Drug Administration (FDA)

www.fda.gov

Mettler-Toledo GmbH
CH-8606 Greifensee, Switzerland
www.mt.com/ind-food-guides
Tel: +41-44-944 22 11 For more information

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364116 / Marcom Industrial

75
 Foreign Body Detection
X-ray Inspection
X-ray Inspection

X-ray inspection technology is used in food, pharmaceutical and related industries,

to ensure product safety and quality. Manufacturers use x-ray inspection systems
to detect foreign bodies and perform in-line quality checks to avoid product recalls.

X-ray inspection technology not only offers exceptional

ferrous, non-ferrous and stainless steel detection, it is
also extremely good at detecting other foreign bodies
such as glass, mineral stone, calcified bone, high
density plastics, and rubber compounds. In addition,
x-ray systems can be used to perform a wide range of
in-line quality checks including:
• Measuring zoned and gross mass
• Counting components
• Identifying missing or broken products
• Monitoring fill levels
• Inspecting the integrity of a product seal or closure
• Checking for damaged product and packaging
• Detecting agglomerates such as flavour and
powder lumps
• Measuring head space

Food manufacturers are under pressure to adopt Contents

the standards of the Global Food Safety Initiative 1 The Case for X-ray Inspection
(GFSI). Other directives and standards such as HACCP 2 How X-ray Inspection Systems Work
(Hazard Analysis Critical Control Points) and GMP
3 X-ray Inspection System Design
(Good Manufacturing Practice) require food and phar-
maceutical manufacturers to make their processes 4 Summary
as safe and transparent as possible. 5 Additional Resources

This chapter explores why x-ray inspection could be

the solution, how x-ray inspection technology works
and looks at effective x-ray inspection system design.

76
 1 The Case for X-ray Inspection

With increasing line speeds and growing consumer OEE (Operational Equipment Effectiveness) can be
expectations, manufacturers are under pressure to increased through x-ray inspection providing pack
X-ray Inspection

adopt more reliable product inspection methods. integrity and allowing manufacturers to manage
quality control within their supply chain.
A well-designed x-ray inspection programme can help:
• Minimise contaminants such as metal, glass, stone, An x-ray inspection system helps manufacturers dem-
bone, high density plastics, and rubber compounds. onstrate their commitment to guidelines and standards
• Reduce costs caused by customer complaints, safe- such as HACCP and to effectively manage process
ty scares and product recalls. risks.
• Protect consumers and brand reputation by ensuring
consistent quality and product safety.

2 How X-ray Inspection Systems Work

X-rays are an invisible form of electromagnetic radia- An x-ray system is essentially a scanning device that
tion like radio waves. Their short wavelength allows captures a grey-scale image of the product which is
them to pass through materials that are opaque to vis- compared to a predetermined standard (Figure 1).
ible light. But they don’t pass through all materials
with the same ease. In general, the denser the materi- On the basis of the comparison, the system accepts or
al, the fewer x-rays that pass through. Hidden contam- rejects the image. If rejected, a rejection signal is sent,
inants, like glass and metal, show up under x-ray in- removing the product from the production line.
spection because they absorb more x-rays than the
surrounding product.

Figure 1

METTLER TOLEDO © 11/2016 - X-ray Inspection 77

 3 X-ray Inspection System Design

An x-ray inspection system consists of an x-ray gener- system which is fully described in ISO 13849-1. Power
ator, a detector and a control system encased in a isolators should be lockable and emergency stops
X-ray Inspection

stainless steel cabinet with a highly visible lamp stack must be fitted at every operator station. Emergency
that signals the system status. stops should be used as a back-up for safeguarding
measures and not a substitute for them.
Food and pharmaceutical x-ray inspection systems
are built for tough environments, can be run at high Cabinet design
line speeds, and detect very small contaminants. X-ray inspection cabinets should be stainless steel
They should be easy to set up, clean and maintain to sealed to minimum IP65 rating as standard or IP69
improve quality without reducing efficiency. for harsh wash-down environments with greater in-
gress risk.
Despite widespread use of x-ray inspection, few guide-
lines exist to help manufacturers evaluate system fea- Systems should include air conditioning or heat ex-
tures or compare machines. Knowing how system de- changers to keep internal electronics safe in a sealed
sign affects day-to-day production can help identify cabinet. A basic open fan is not enough as it reduces
the best system for a particular application. the cabinet’s rating below IP65. Air conditioning elimi-
nates water use. A built-in gauge should indicate
Health and safety overheating. A mains suppressor, filter and UPS (unin-
X-ray inspection systems must be built to comply with terruptable power supply) should be included to en-
safety standards to ensure all personnel and produc- able controlled shutdowns during power failures.
tion staff are safe when operating the equipment. For
example, x-ray inspection systems must meet ionising Conveyor design
radiation regulations for the country where the ma- The conveyor belt should be removable without tools
chine is used. and incorporate a quick-release tension roller. Tracking
must also be simple to adjust. On wide-belt – typically
Some x-ray manufacturers have safety barrier photo- over 800 mm – or very wet/greasy applications, auto-
cells across the machine’s entry points. When the matic tracking should be considered. Misaligned belts
photocell is blocked for an extended period the belt can cause substantial downtime, due to premature
stops. This protection method also may not be accept- wear.
able, for certain countries.
For bulk-flow applications, troughed belts or side-
The requirement for a Category 3 (dual circuit) safety skirted belts retain product, minimise spills and im-
interlock design is driven by a risk assessment scoring prove transport.

78 METTLER TOLEDO © 11/2016 - X-ray Inspection

 Hygienic design products are suited more to beryllium. The lower ener-
Environment and cleaning regime must be considered gy and softer rays improve detection of medium-den-
before purchase. Design should: sity contaminants such as glass, mineral and bone
• Eliminate cavities/bacterial traps and lend themselves to bulk-flow, small thin-pack and
• Seal hollow sections product-in-seal inspections.
X-ray Inspection

• Avoid ledges/horizontal surfaces,

• Use open, continuous-weld, easy-access frames X-ray detector
• Allow hygienic electrical cable, trunking and pneu- Various diode sizes are available to suit a diverse
matic service management range of applications. Product depth, size and pro-
duction line speed must all be considered during the
Drainage slots in catch trays and easy strip belts selection process.
should be used whenever possible to ensure thorough
cleaning in high-risk applications. User-friendly interface
Full-colour touch-screen displays with intuitive soft-
Pipeline systems should incorporate clean-in-place ware and different user access levels allow quick set-
(CIP) procedures, allowing hot fluid flush with no need up and reduce errors. Added displays allow remote
to disassemble the manifold or disconnect pipes. visibility. Multiple language options allow operators
Aseptic manifolds with double O-ring seals for x-ray to select the most appropriate.
connections allow injected steam to kill microorgan-
isms in sterile applications. Variable speed
Advanced systems should match scanning speed
Good hygienic design helps HACCP compliance. 3-A, and reject timing to line speed. Image proportions
AMI, EHEDG and NSF machine design standards are and sensitivity should be made for the speed range.
also highly regarded and offer additional information
on this topic. For more information please see the Ad-
Adaptive filtering
ditional Resources section at the end of this chapter.
For dense-edged containers e.g. glass jars, adaptive
technology allows high-absorption areas to be filtered
X-ray tube out. Fixed-width filters, by contrast, may let contami-
X-ray tubes should match the application. Glass-win- nants pass or cause false rejects.
dowed tubes are common. Low-density/low-depth

METTLER TOLEDO © 11/2016 - X-ray Inspection 79

 Information storage
Many x-ray systems are PC based and record large
amounts of useful information, so the Control Panel
should be specified to provide sufficient processing at
all times. Features such as USB and Ethernet ports al-
X-ray Inspection

low immediate access to statistical data and the reject

library. This access helps with reporting, traceability
and HACCP compliance.

Diagnostics
Well-designed inspection systems will use self-moni-
toring software that continually checks machine oper-
ation to flag potential problems. It can flag up a poten-
tial problem in advance, so as to provide an early Figure 2
warning system, plus a field-based service engineer
can also dial into the machine remotely via Ethernet to
fix faults or prepare parts for a site visit. The lamp stack also alerts operators that a PVR (Per-
formance Verification Routine) is required. It can also
Failsafe system indicate activation of any of the failsafe features,
A highly visible lamp stack with a top beacon should namely reject confirmation, bin-full warning and low
be visible from 360 degrees around the machine air pressure. An audible alarm is usually activated at
(Figure 2). It indicates that x-rays are on/off, that the same time.
x-rays are about to start up, that the system is in fault
mode, and that power is on the machine and the
system is healthy.

4 Summary

X-ray inspection systems involve significant capital in- Food and pharmaceutical x-ray inspection systems
vestment. Equipment must be well-designed to ensure should be easy to set up, clean and maintain to im-
ROI (Return on Investment). Cost savings, regulatory prove quality without reducing efficiency. They must
compliance, consumer/brand protection, and en- offer durability and accuracy during high-speed opera-
hanced sales can justify the initial expense. A well tion. Safety, hygiene, cabinet/conveyor/x-ray tube de-
specified and reliable installation will also help to sign and data collection capabilities should be consid-
maximise OEE (Overall Equipment Effectiveness) on ered for optimised selection.
the line.
The capability of x-ray inspection systems to detect a
The short wavelength of x-rays allows them to pass range of contaminants can help manufacturers prove
through materials opaque to visible light. Because appropriate risk management. X-ray detection can
they do not pass through all densities with similar also be considered the highest level of inspection in a
ease, they detect contaminants, which absorb more x- diligent HACCP program.
rays than surrounding product.

80 METTLER TOLEDO © 11/2016 - X-ray Inspection

 5 Additional Resources

• METTLER TOLEDO Safeline X-ray Inspection Guide serves as a definitive reference work for development
of an effective x-ray inspection program. Request your free copy at
X-ray Inspection

www.mt.com/safeline-xray

• METTLER TOLEDO On-demand webinars also allow 24/7 self-paced learning on a wide range of important
process integration topics
www.mt.com/pi-ondemand

Several regulatory bodies advocate x-ray inspection. For more on emerging standards and other helpful
information, please visit the following:

• 3-A standards organization

www.3-a.org

• European Hygienic Engineering & Design Group EHEDG

www.ehedg.org

• National Sanitation Foundation NSF International

www.nsf.org

• American Meat Institute AMI

www.meatinstitute.org

• British Retail Consortium BRC

www.brcglobalstandards.com

• International Food Standard IFS

www.food-care.info

• ISO 22000:2005 – Food Safety Management System Standard

www.lrqa.co.uk/certification/food/iso22000

• Safe Quality Food (SQF) Institute

www.SQFI.com

Mettler-Toledo GmbH
CH-8606 Greifensee, Switzerland
www.mt.com/ind-food-guides
Tel: +41-44-944 22 11 For more information

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364117 / Marcom Industrial

81
 Reliable Vehicle Weighing
Vehicle Weighing
Helps Protect Profits

Moving bulk goods or raw materials into or out of a processing facility effectively is critical
to plant productivity. As a result, unplanned truck scale downtime can seriously impact the
total product output of a processing plant and threaten profit margins.

Primary causes of unplanned downtime in traditional

truck-scale systems include:
• Harsh conditions, including water ingress, damage
to load cells, junction boxes, and scale terminals,
and lightning-generated surges
• Heavy loads and high traffic volume, which contrib-
ute to issues such as scale drift, and cause de-
creased accuracy over time
• Rodent and debris damage which can affect the in-
tegrity of cables and wiring

Many companies believe unplanned downtime to

maintain or repair truck scales is unavoidable. Howev-
er, unplanned scale downtime does not have to be an
accepted variable in the productivity equation. Newer
scale technologies, such as microprocessor-equipped
load cells and systems that eliminate junction boxes,
have many advantages over older technology. Contents
1 The Importance of Reliable
This paper addresses technology and design advanc- Vehicle Weighing
es that help eliminate unplanned downtime such as 2 Enhancing Accuracy:
self-monitoring load cell networks, which keep scales Microprocessors within Load Cells
operating and help ensure in-plant productivity gains
are not made in vain.
3 Reducing Physical Threats:
Innovative Product Design
4 Considering ROI
5 Summary
6 Additional Resources

82
 1 The Importance of Reliable Vehicle Weighing

The crucial reason a truck scale must perform is sim- Problems such as load cell fluid leaks in a hydraulic
ple: Every minute a scale weighs inaccurately – or not system can decrease weighing accuracy and effective-
Vehicle Weighing

at all – costs money. Without correct amounts of in- ness, and can also be difficult to troubleshoot. The
coming materials, critical processes are put on hold. slower response time of hydraulic load cells can also
Additionally, in-plant productivity gains can be nullified mean fewer trucks are processed through the line.
if goods are waiting to be shipped out.
Another significant issue for traditional scale systems
Internal/external scale influences is lightning. A lightning strike can put an unprotected
There are many reasons that truck scales can be the vehicle scale out of service in an instant. Some scale
Achilles’ heel of a processing or production operation. companies provide warranties for lightning strikes, but
Scale systems that use conventional analog load cells, when one occurs, you are still faced with considerable
hydraulic load cells, sectional controllers, and even downtime during a repair or replacement. Over the
digital junction boxes, have weaknesses that can ei- years, lightning protection systems have been devel-
ther slow down weighing operations or leave a scale oped, but even so, not all are created equal. Many
system open to errors or harm from both internal and manufacturers claim to offer lightning protection, but
external factors. The influences that can affect conven- have not actually tested their systems to evaluate ef-
tional strain gauge load cells include: fectiveness.

• Temperature The cost of weighing errors

• Voltage variation Because conventional scale systems cannot alert op-
• Non-linearity erators to the above issues or compensate for their in-
• Hysteresis fluence, they can continue to produce undetected
• Creep weighing errors. In fact, the errors can often exceed
• Instability the limits established for certified legal-for-trade appli-
• Zero change cations. The more vehicles that are weighed, the more
• Sensitivity change the losses add up.

Many traditional systems use junction boxes which Perhaps even worse, customer complaints may be the
are naturally difficult to seal and deteriorate with time. first indicator that a scale is in trouble. Of course, a
This leaves them highly susceptible to moisture in- manufacturer never wants outside entities such as a
gress, causing corrosion and damage to the electrical customers, auditors, or regulatory bodies to be the
connections inside. Without networked self-diagnos- ones who bring inconsistent weighing results or other
tics, such issues may not be discovered for weeks. quality control issues to the foreground. A scale’s per-
This can mean the scale is providing inaccurate formance can not only affect profit and productivity,
weights without the operator knowing. Even once an but an organization’s reputation as well.
error is noticed, diagnosis is a challenge and can re-
quire lengthy inconvenient downtime to trace the
cause and correct it. Junction boxes are in fact a lead-
ing cause scale system downtime.

METTLER TOLEDO © 11/2016 - Vehicle Weighing 83

 2 Enhancing Accuracy and Uptime:
Microprocessing within Load Cells
Vehicle Weighing

Innovative technology can provide the first-line de- • weighing errors

fense against costly weighing errors. • overloading
• environmental conditions affecting accuracy
The place to start may be to replace any analog load • network health
cells with load cells that are equipped with on-board • load cell voltage drops
microprocessors that transmit strong digital signals • cell enclosure integrity
and provide self-diagnostics.
Operators are alerted to problems instantly so they
Microprocessors within each load cell can provide can be fixed. This saves time and scores of potentially
computing power to help assure a manufacturer that a inaccurate inbound or outbound truckloads.
vehicle scale is working properly. They can alert scale
operators to performance indicators and potential Scheduling maintenance
problems. Often this allows potential problems to be Through the use of advanced digital load cell technol-
prevented through routine maintenance, or allows a ogy, diagnostic log files record performance trends
user to pinpoint the source of an immediate problem and help predict problems before they occur. These in-
for quick intervention and correction. ternal preventative maintenance systems alert supervi-
sors about issues on the screen of the scale terminal,
Monitoring weighing performance or via email or text message.
The key to increasing a load cell’s weighing accuracy
is reducing the effect of internal and external influence This allows maintenance to be scheduled when it is
factors. A load cell that incorporates digital signal pro- most convenient. Time-consuming troubleshooting
cessing technology can monitor and greatly reduce and parts swapping are replaced by prevention and
the affects of internal and external influences on detailed data analysis. Unplanned downtime is avoid-
weighing accuracy. This process is known as digital ed and operating costs are reduced.
compensation. With on-board microprocessors and
advanced software, each load cell can correct or alert
operators to:

3 Reducing Environmental Threats:

Innovative Product Design
While enhanced load cell technology can help make Heavy-duty stainless construction
critical gains in reliability, the physical design of Heavy-duty, corrosion-resistant stainless steel helps
the load cell system can also help ensure costly resist damage in abusive or corrosive environments.
unplanned downtime is avoided. Several important Critical weighing electronics are now being protected
considerations for the weighing system’s physical like never before within hermetically sealed, IP68/
design follow. IP69K watertight systems. A fully welded enclosure
and watertight connectors can ensure that flooding will
not impact a company’s maintenance budget.

84 METTLER TOLEDO © 11/2016 - Vehicle Weighing

 Junction box elimination Eliminating all junction boxes means fewer compo-
Junction boxes – which contain sensitive electronics nents that could be damaged through water ingress or
easily affected by moisture – are wired by hand in the lightning strike as well. Junction box removal reduces
field during a complex installation process on tradi- the number of connections in a vehicle scale by at
tional scales. They are a common cause of vehicle least 25% compared to systems with junction boxes.
Vehicle Weighing

scale failures because the electronics are not protected

from environmental elements by a permanent seal. Junction box removal reduces the number of connec-
Newer digital systems do not require a junction box or tions in a vehicle scale by at least 25% compared to
complex wiring by hand, greatly simplifying the instal- systems with junction boxes. Eliminating all junction
lation process and future maintenance. Electronics in boxes also means there are fewer components that
newer systems can be housed within the laser welded could be damaged through water ingress or a light-
stainless steel load cell enclosure. ning strike.

A hermetically sealed ten load cell

network with no junction boxes

Double-shielded cables connector styles have been pioneered in the harshest

Traditional load cell cables use a polyurethane jacket military and medical applications where electronics
over the conductor wires. These cables are easily cut performance can literally be a matter of life-and-death.
or damaged in rugged environments. Newer systems
use stainless steel cables, which ideally are double- Breach detection
shielded. This prevents physical wear, rodent damage, In addition to heavy-duty, hermetically sealed enclo-
electromagnetic interference, and also provide integral sures, a built-in breach detection system can alert an
protection against lightning strikes. operator to accidental load cell puncture or tampering.
Even the smallest of holes can allow humidity into the
Quick-release connectors load cell, which typically leads to weighing errors and
Rapid and secure connectivity is critical during routine failures. Unlike a conventional load cell, systems with
maintenance. Quick-connect IP68 watertight load cell built-in breach detection allow for identification and re-
cables enhance connectivity and allow operators to placement of damaged components before moisture
get a scale back in service quickly. These watertight ingress causes real problems.

METTLER TOLEDO © 11/2016 - Vehicle Weighing 85

Vehicle Weighing

Laboratory lightning testing

Lightning strike protection scale system including load cells, cables, and termi-
A lightning strike can put a vehicle scale out of service nal. Internal on-board surge protectors redirect voltage
in an instant. Even if a warranty or insurance policy surges away from sensitive electronics, creating a bar-
covers repair costs, a manufacturer still faces the cost rier of protection. Single-point grounding keeps scales
of business lost every day the scale is not operating up and running in circumstances where electrical
during the logistics of a repair or replacement. This damage would previously have knocked a scale out of
makes high-quality integrated lightning strike protec- operation. The average lightning strike is 30k am-
tion a significant long-term value-added feature. peres, but can be higher. Ideally, a built-in lightning
surge protection system should withstand up to a 40k
Real lightning damage prevention systems exist. Mod- amp surge, as tested by International Electrotechnical
ern lightning protection can shield an entire vehicle Commission IEC62305-1.

4 Considering ROI

In a particularly high-volume situation, avoiding just A METTLER TOLEDO weighing expert can help assess
one day of downtime can offset the cost of a new vehi- the real impact downtime is making on a company’s
cle scale system. The elimination of unplanned service vehicle weighing system and suggest an appropriate
events can result in significant savings and productivi- alternative or existing scale modification. A modern
ty increases that continue to add up over the life of a upgrade should pay for itself in both low- and high-
reliable, fully supported vehicle scale solution. volume operations in less than 12 months – and
sometimes in as few as one or two months.

5 Summary

No matter how excellent in-plant operations are, pro- and lightning strikes because of their outdoor nature.
cessing gains can be lost when goods cannot flow A lightning strike can knock out an unprotected vehicle
into or out of a production facility due to unplanned scale and water ingress can short out wiring in poorly
truck scale downtime. sealed junction boxes.

Truck scales face risks inherent to all weighing sys- Analog scales cannot alert operators to these
tems, as well as unique risks such as water damage issues. However, a fully digital scale equipped with

86 METTLER TOLEDO © 11/2016 - Vehicle Weighing

 microprocessor-based digital signal processing Physical design features such as hermetically sealed
technology can: load cells, junction-box elimination, quick-release/ro-
dent-proof connectors and cables, breach detection,
• assure proper operation and lightning strike protection can help ensure day-in,
• alert users to potential problems for quick day-out operation. These features, coupled with net-
Vehicle Weighing

intervention worked self-diagnostics can drastically increase reli-

• self-diagnose and correct for many issues ability and longevity, while reducing overall mainte-
• provide highly accurate weighing under a variety nance requirements.
of environmental conditions
Upgrading an existing vehicle scale with new ad-
Certain digital load cells also simplify installation vanced weighing electronics can offer a rapid financial
and reduce failures because no junction boxes, payback, thanks to greater uptime. A system that
analog-to-digital converter boxes, or gathering cards incorporates these important innovations can offer
are required. peace of mind when it comes to your truck scale.

6 Additional Resources

Please review the following resources for additional information on vehicle scale solutions.

• White Paper: Digital Compensation in POWERCELL Load Cells

www.mt.com/global/en/home/supportive_content/product_information.VEH_comp.twoColEd.html

• METTLER TOLEDO POWERCELL

www.mt.com/POWERCELL

Mettler-Toledo GmbH
Industrial Division
www.mt.com/ind-food-guides
CH-8606 Nänikon, Switzerland For more information
Tel. + 41 44 944 22 11

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364130 / Marcom Industrial
87
 Moisture Analyzer
Moisture Analysis
Routine Performance Testing

Moisture affects the processibility, shelf life, usability and quality of many food products.
Errors when conducting moisture analysis may negatively impact quality results and
influence product prices. This white paper offers guidance on how to optimize moisture
content determination and instrument performance.

Most products and ingredients have optimum moisture

content for obtaining the best possible processing re-
sults and therefore attaining maximum quality. Further-
more, moisture content impacts on price and there are
statutory rules for some products governing the maxi-
mum permissible moisture content (e.g. as defined by
national food regulations). This means that trade and
industry need to determine moisture content levels.

To run measurement equipment and analytical instru-

ments in a quality system, industry specific regulatory
requirements often have to be followed. But regulatory
guidance is commonly not very specific. They do not
offer specific statements as to how the guidelines
should be achieved in everyday practices. Questions
such as “How often should I test my instrument?” are
not answered.
Contents
This white paper describes the influences and sources 1 Influences on Accuracy
of error which may be present when conducting mois- 2 Accuracy of Moisture Analyzer Results
ture analyses. It discusses the routine tests which are
3 Routine Testing of Moisture Analyzers
necessary to ensure reliable determination of the mois-
ture content and correct functioning of the instrument. 4 Summary
The recommended tests and their frequencies are pre- 5 Additional Resources
sented in the framework of a risk-based approach.

88
 1 Influences on Accuracy
The accuracy of moisture analyzer results may be Safety factor
influenced by several factors. The most important are Reproducibility of the moisture content as determined
Moisture Analysis

variability of the heating temperature, of the weighing from a limited number of measurements will vary,
results and of the sample characteristics. In this white even if the setup is left unaltered. Besides these sta-
paper we elaborate on how these influences on the tistical variations, environmental conditions, sample
accuracy affect the final drying result and how these handling and different operators influence the perfor-
influences can be controlled by performing appropriate mance of the moisture analyzer. It is therefore recom-
routine testing. It is important to know that there are mended to apply a safety factor to stay within the de-
two types of influences that can limit the performance fined acceptance criteria. It is good practice to define
of an instrument - permanent and temporary influ- two different acceptance criteria, the warning and the
ences. control limit. The control limit represents the limit value
which has to be adhered to in order to satisfy the
Permanent influences occur and persist. They limit the required accuracy. The warning limit is defined as the
accuracy of the moisture analyzer and will be detected control limit divided by the safety factor and provides
when the next performance test is carried out. They do an early warning to indicate that the accuracy of the
not disappear until a corrective action has been taken. moisture determination might deteriorate. It is recom-
Temporary influences limit the accuracy of a moisture mended to apply a safety factor of minimum 2 by de-
analyzer only for the duration of the influence. The fault to compensate for the variations. The safety factor
limitation on the accuracy will disappear without any should be increased in accordance with the strength
intervention or corrective action as soon as the influ- of the expected influences. I.e. in rough environments
ence has stopped. a higher safety factor should be applied.

Routine test Temporary Routine test

influences

Control limit

Warning limit

Accuracy of
moisture determination

Figure 1: Temporary influences may affect the accuracy of a moisture analyzer without being detected by a routine test. The safety factor
builds a margin between the warning and control limits to lower the probability that measurements exceed the control limit even if tempo-
rary external influences reduce the accuracy.

METTLER TOLEDO © 11/2016 - Moisture Analysis 89

 2 Accuracy of Moisture Analyzer Results
The following chapters focus on the main permanent • How strong are the influences with regard to the
influences that affect the determination of moisture accuracy of the moisture determination?
Moisture Analysis

content. To find out what the main influences are and • What measures can be taken to control these
what measures are meaningful in terms of quantifying influences?
the accuracy of a moisture analyzer, the questions
below need to be answered. Variability in moisture analyzer results is mainly influ-
• What causes variations of moisture content results enced by three elements: the heating unit, the weigh-
[%MC] in a moisture analyzer? ing unit and the sample itself.
• Where do these influences come from?

Heating unit

If the heating temperature is too high:

• Components may oxidize, burn or combust.
• Properties of the substance change and not all
moisture can evaporate (e.g. paint or glue forms
a skin when the drying temperature is too high).

Temperature elasticity of the sample

It is important to know how susceptible the sample is
to the variations in heating temperature. For some
substances, the result of the moisture determination
Heating temperature variability (%MC) barely changes even when the heating temper-
Possible reasons for variability of the heating ature changes considerably. Other substances show
temperature are: large differences in moisture content when the heating
• The heating unit is not adjusted correctly or has not temperature varies only slightly. The degree to which
been adjusted on site, under working conditions. the %MC result of a sample is affected by a tempera-
• The instrument location has changed since the last ture change in °C is called “temperature elasticity”.
adjustment/calibration. Therefore, the amount of influence from an erroneous
• The protective glass or reflector is contaminated. temperature change depends on the temperature elas-
• The temperature sensor is defective or contaminated. ticity of the sample.
• The temperature calibration kit is defective. • High temperature elasticity
• The correction values of the temperature calibration Substances with high temperature elasticity exhibit a
kit were not applied correctly during temperature big change in the moisture content result with just a
adjustment. small change in heating temperature (typically or-
ganic substances).
Impact of temperature variability • Low temperature elasticity
on the moisture result Substances with low temperature elasticity need a
If the heating temperature is too low: big change in the heating temperature until an influ-
• Not all moisture is able to evaporate since lower ence on the moisture content result is visible (typi-
layers of the sample are not heated enough. cally inorganic substances).
• Only a certain part of the moisture evaporates
(e.g. ethanol but not water).
• Only the surface water but not the crystal water
evaporates.

90 METTLER TOLEDO © 11/2016 - Moisture Analysis

 Weighing unit A nonlinearity error has no considerable influence on
the moisture content result as the weight loss due to
There are several properties which limit the perfor- the drying process is generally small compared to the
mance of the weighing unit. The most important are balance capacity.
repeatability, eccentricity, nonlinearity and sensitivity.
Moisture Analysis

Consequently, routine nonlinearity tests by the user

Sensitivity are not recommended.
Sensitivity is the ratio between the weighing value (in-
dicated on the balance) and the actual mass of the Repeatability
reference weight. A sensitivity of 1 (one) means that Repeatability is the ability of a weighing instrument
the displayed mass value equals the mass of the ref- to provide identical results when the same load is
erence weight. The evaluation of the moisture content placed several times and in a practically identical
[%MC] is based on the difference between the wet way on the weighing pan under reasonably constant
sample weight and the dry sample weight. Determin- test conditions. Repeatability is the dominant error
ing the moisture content is based on relative weight for small sample weights. It influences both readings
measurements. Hence sensitivity has no impact on (wet weight and dry weight). However, repeatability
the moisture result. has a very small influence on the accuracy as com-
pared to a possible temperature deviation between
Eccentricity the programmed target temperature and the actual
Eccentricity is the deviation in the measurement value temperature.
caused by eccentric loading, in other words, asym-
metrical placement of the load on the weighing pan.
Generally, the eccentricity error has no considerable Relevance of deviations of
influence on the moisture content result: Firstly, the heating unit and weighing unit
weight loss due to the drying process is usually small
compared to the balance capacity, and secondly, the In general, measurement errors due to deviations
sample is not moved during drying. between the programmed target temperature and the
actual temperature are more likely and have a higher
Consequently, eccentricity is not a dominant contribu- impact on the accuracy of the %MC results than mea-
tor to the measurement uncertainty and routine eccen- surement errors due to the influence of repeatability
tricity tests by the user are not recommended. of the weighing unit. Also the impact of a change in
heating temperature is larger for samples with higher
Nonlinearity temperature elasticity.
The ideal characteristic weighing curve of a balance is
a straight line through the measurement points of no- Hence, tests that detect temperature deviations
load and full load (nominal weighing capacity). Non- (SmartCal, temperature calibration) are more often
linearity is the deviation of the indicated weighing val- required than weighing performance tests.
ue from this straight line.

3 Routine Testing of Moisture Analyzers

Maintaining the accuracy of an instrument and reduc- User

ing the risk of being out of specification requires test- In between maintenance and calibration by the service
ing by the service provider and the user. provider, the user should perform routine tests to mon-
itor the most important parameters influencing mea-
Service surement accuracy.
By calibrating all measurement components of the in-
strument using traceable standards and manufacturer Instrument
SOPs, the service provider provides a comprehensive Many state-of-the-art instruments include built-in test
statement of the instrument’s condition. and adjustment functionalities, as well as software

METTLER TOLEDO © 11/2016 - Moisture Analysis 91

 and hardware features (e.g. LevelControl) that help to maintenance where all parts are cleaned and the func-
avoid measurement errors. tions of all components are tested before calibration.

Hierarchy of tests – temperature The calibration of the weighing unit comprises the
versus weighing comprehensive tests of the weighing parameters. If de-
Moisture Analysis

As described above, measurement errors due to devia- viations from manufacturer tolerances are detected, an
tions between the programmed target temperature and adjustment is carried out. The calibration of the heat-
the actual temperature are more likely and have a ing unit using the temperature calibration kit is per-
higher impact on the accuracy of the %MC results formed against manufacturer tolerances. If deviations
than measurement errors due to the influence of re- occur, an adjustment is performed. All calibration re-
peatability of the weighing unit. Weighing is a more sults are documented and handed out to the user.
stable and controlled process than heating. Hence, the
risk stemming from the weighing unit is rather low, as SmartCal test (by user)
long as no defect occurs. The SmartCal test substance is highly temperature
elastic and contains a specific amount of moisture
Therefore, the main reason to test the weighing unit is which makes it an ideal test substance for verifying
to check its proper functioning and/or detect defects. the performance of moisture analyzers. Specific con-
This can be done by performing periodic sensitivity trol limits for the SmartCal test are recommended by
tests. Periodic testing of eccentricity, nonlinearity and METTLER TOLEDO.
repeatability is not as important and can be done by
the service technician within the framework of periodic A defect or substantial inaccuracy will be detected with
maintenance when performing a calibration. Tempera- SmartCal by showing a result outside the SmartCal
ture deviations are more likely and have a bigger im- control limits.
pact on the moisture result than variability in weighing.
The impact depends on the temperature elasticity of Sensitivity test (by user)
the sample. Performing the sensitivity test delivers an indication of
incorrect adjustment of the weighing unit as well as
defects of the weighing cell that require more in depth
Conclusion
diagnosis before further use of the moisture analyzer
The frequency of tests that focus on temperature
(e.g. defect due to improper transportation).
should be higher than tests that focus on the weighing
accuracy. Moisture analyzers that are used to measure
Temperature calibration (by user)
the moisture content of samples with higher tempera-
Temperature calibration is performed by using a tem-
ture elasticity require more frequent testing than those
perature calibration kit as a reference. Performing a
used for samples with lower temperature elasticity.
temperature calibration indicates the condition of the
heating unit. Temperature deviations due to changes
Recommended tests in the environment, will be detected.
During the routine operation of a moisture analyzer
only those tests are recommended which deliver a
Test or adjustment with built-in reference weight
meaningful statement with regards to controlling the
(by instrument)
quality of the measurement result.
Testing and adjustment mechanisms built into instru-
ments consist of one or more reference weights, and a
Calibration and adjustment of weighing loading mechanism that is activated either manually
and heating unit (by service engineer) or automatically. Such a mechanism allows conve-
Calibration by a service engineer is an extensive test nient testing and/or adjustment of the sensitivity of the
of all important parameters of a moisture analyzer. weighing instrument.
Preferably, a calibration is combined with preventative

92 METTLER TOLEDO © 11/2016 - Moisture Analysis

 4 Summary

Deviations of a moisture analyzer are mainly influ- By service engineer

enced by the heating unit, the weighing unit and the • Calibration & adjustment
Moisture Analysis

sample.
By instrument
Temperature deviations are more likely than weighing • Test with built-in reference weight
deviations and have a bigger impact on the moisture (FACT, by instrument)
result.
The frequency of each routine test depends on the risk
The following tests are recommended for performance that is associated with the measurement process.
monitoring of a moisture analyzer:
For more detailed information, read the full white paper
By the user ‘Routine Testing Moisture Analyzer’:
• SmartCal test
• Sensitivity test (SmartCal test can be done instead) www.mt.com/moisture-routine-testing
• Temperature calibration (SmartCal test can be done
instead)

5 Additional Resources

• Moisture analyzers, METTLER TOLEDO • White Paper: Drying Oven vs. Halogen Moisture An-
www.mt.com/moisture alyzer – A Practical Guide to Compare Methods,
METTLER TOLEDO
• Method Collection: Find Your Moisture Method for www.mt.com/moisture-or-oven
Food, METTLER TOLEDO
www.mt.com/moisture-food-methods

Mettler-Toledo GmbH
CH-8606 Greifensee, Switzerland
www.mt.com/ind-food-guides
Tel. +41 44 944 22 11 For more information
Fax +41 44 944 30 60

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364120 / Marcom Industrial
93
 Efficient Quality Management
Quality Management
in a Regulated Environment

Ensuring compliance with quality management and regulatory standards, such

as ISO or GMP, requires an understanding of parameters influencing the accuracy
of weighing processes. In highly regulated industries where consumer safety
is at stake – such as food, cosmetics, pharmaceutical or automotive production –
it can also mean being subjected to frequent audits.

Before acquiring weighing system and instrument verifi-

cation, performing a thorough risk analysis between
service visits can help put regulatory guidelines into ef-
fective practice, while reducing costs and increasing
productivity and product safety. Helpful actions include:
• Determining required process tolerances
• Selecting appropriate technology
• Documenting compliance
• Setting adequate testing and calibration schedules
• Choosing appropriate performance measures

Instituting relatively simple weighing tests as part of

standard operating procedures (SOPs) can help
ensure top quality product and audit results. Good
Weighing Practice™ (GWP®), the global weighing
guideline developed by METTLER TOLEDO, can help,
regardless of the manufacturer of a particular scale
or balance. Contents
1 Putting Quality Management in Perspective
2 Establishing an Appropriate Weighing
Practice
3 Matching Instrument Accuracy to Process
Tolerance
4 Understanding Process Risks
in a Regulatory Context
5 Verifying Equipment Accuracy
6 Summary
7 Additional Resources

94
 1 Putting Quality Management in Perspective

Weighing process quality was once primarily a ques- Questions left to interpretation include:
tion of accuracy. However, it has become increasingly • How should verification be made? At what interval?
Quality Management

concerned with risk evaluation and management Using which standard?

and is the daily preoccupation of quality managers • How should validity of results be assessed?
worldwide. Recorded?
• What action should be taken?
Quality assurance complexity often arises from the
regulations themselves. They give only a vague frame- Putting the weighing process itself at the center
work on performance targets. No concrete implemen- of the quality management equation can help
tation information is given based on the assumption establish helpful, documentation-ready SOPs that
that the user knows his or her process best – and can pass audits and improve productivity and profitability.
therefore choose the best solution to any issue. METTLER TOLEDO’s GWP® offers a framework
in nearly any regulatory scenario, regardless of
a weighing system’s manufacturer.

For example, take this weighing practices excerpt from ISO 9001:

ISO 9001: 7.6 Control of monitoring and measuring devices

Measuring devices shall be calibrated or verified at specific intervals, or prior to use, against measure-
ment standards traceable to international or national measurement standards. The organization shall
assess and record the validity of the previous measuring results when the equipment is found not
to conform to requirements. The organization shall take appropriate action on the equipment and any
product affected.

METTLER TOLEDO © 11/2016 - Quality Management 95

 2 Establishing an Appropriate Weighing Practice

METTLER TOLEDO’s GWP® offers a framework to es-

tablish a weighing practice that works. The five basic
Quality Management

GWP® steps follow:

STEP 1: Good evaluation

Evaluate the process from a metrological perspective Good Evaluation
to establish parameters, such as smallest net weight
and required process accuracy. These parameters set
expectations for a given instrument.

STEP 2: Good selection

Select a scale that fulfills the preceding requirements, Good Selection
or matches the accuracy to the process needs. The
minimum weight concept is used as a basis for selec-
tion.

STEP 3: Good installation

Good Installation
Document that appropriate installation – unpacking,
set-up, configuration, calibration, adjustment and
operator training – has taken place and that the equip-
ment still fulfills selection requirements.

STEP 4: Good calibration

Calibrate a scale in its operating environment. Docu-
Good Calibration
menting scale performance and issuing applicable
certificates at regular intervals is the qualified tech-
nician’s task.

STEP 5: Good operation

Establish SOPs and test schedules to help guarantee Good Operation
that weighing process criteria are fulfilled between
service visits.

Each step involves assessment of process parameters

to ensure equipment can meet tolerances and quality
requirements.

96 METTLER TOLEDO © 11/2016 - Quality Management

 3 Matching Instrument Accuracy to Required Process Tolerance

A weighing system’s life starts with assessing process Quality will be assured if an instrument’s measure-
requirements from a metrological perspective. This ment uncertainty is always better than the acceptable
Quality Management

means establishing process parameters such as: process tolerance. For example, measuring 1 kg with
• Weighing range a tolerance of 1% is only possible with a scale provid-
• Smallest net weight ing a measurement uncertainty better than 1% (<1%)
• Process tolerance at the given net load of 1 kg.
• Applicable regulations
• Need for safety margin The relative measurement uncertainty of any measur-
ing instrument – particularly a scale – can be assured
Other important concerns include ruggedness of the by considering the following characteristics.
construction, mechanical stress when loading the
scale, hygiene, connectivity and environmental condi- Minimum weight
tions, such as humidity, temperature, ingress pro- In the low range, there will be a limit under which any
tection, explosion/corrosion protection, hygiene and measurement will have an uncertainty greater than the
connectivity. acceptable tolerance. This is called the ‘minimum
weight’ characteristic.

Relative uncertainty becomes bigger at smaller weights

U [kg] = U0 + Constant x Weight

Absolute measurement uncertainty [kg]
Uncertainty U [kg or- %]

Process tolerance (%)

Relative measurement uncertainty [%]

Weight [kg] Max

For smaller weights, the relative measurement uncertainty can be so high

that the weight cannot be trusted anymore!

METTLER TOLEDO © 11/2016 - Quality Management 97

 Smallest net weight In the example (figure 1), it is obvious that Scale 3 is
The smallest net weight of the weighing process not appropriate, because its relative measurement un-
under consideration has to fulfill the required process certainty is greater than the required relative tolerance
tolerance requirement. As each scale will have its at the smallest net weight. Scale 2, taking into account
own absolute and relative measurement uncertainty only the minimum weight, could be a candidate. Upon
Quality Management

curve (see figure 1 on next page), the only scales further investigation, however, we see that Scale 1 is
that are appropriate are those where the minimum the proper selection.
weight characteristic is smaller than the smallest
net weight of the respective process.

Scale 1

Scale 2

Scale 3
Tolerance (in %)

Process tolerance (%)

Smallest net weight Load [kg] Max. 60 kg

Figure 1 – Relative measurement uncertainty (%) of 3 scales of 60 kg

Process tolerance & safety margin A safety factor on the Minimum Weight must be ap-
Instrument performance is strongly influenced by the plied. In other words, the Minimum Weight of a scale
environment. Certain environmental factors, such as air at a given tolerance should be at least half of the
currents, temperature changes and vibrations, can lead smallest net weight to be measured (safety factor >2).
to a reduction in instrument performance, resulting in A safety factor >2 is recommended if risk analysis de-
less accurate weighing. Therefore, some safety margin termines that accuracy is critical. Using these criteria,
must be anticipated in order to prevent external influ- in this example, only Scale 1 can fulfill all process
ences from throwing measurements out of tolerance. requirements.

98 METTLER TOLEDO © 11/2016 - Quality Management

 4 Understanding Process Risks in a Regulatory Context
Industrial processes always carry risk. Errors may im- system in good order and document that the equip-
pact the company (increased costs, loss of image, ment will perform the task for which it was selected.
Quality Management

loss of production time), consumers, the environment However, many users invest large sums in instrumen-
– or all of the above. Errors as a result of a weighing tation but neglect end-user training. Since the user is
inaccuracy may result in over- or under filling, waste often the biggest source of measurement uncertainty,
of production materials, overpaying for materials, this can be a costly error in terms of lost production
quality issues and customer complaints, which may and audit failures.
lead to financial losses for the company.
Establishing audit proof documentation
Mistakes across complex industrial processes may be Calibrating a scale in its operating environment helps
difficult to detect. Identifying, describing and minimiz- document performance under the influence of environ-
ing operational risks has become the focus of most mental factors. Documenting scale performance at
current regulations and quality systems, such as ISO, regular intervals is the task of an authorized and
GMP, IFS, and HACCP. trained technician. He or she will determine the value
of the different contributions to the measurement
High risk and a narrow process tolerance may call for uncertainty such as scale sensitivity, weighing repeat-
frequent instrument accuracy verification. Even under a ability, eccentricity deviation and non-linearity. The
more frequent testing schedule, regulators determine scale will also be serviced so that any deviation from
an instrument’s uncertainty principle based on an as- original specifications is minimized or alleviated.
sumption that proper installation and calibration ac-
tions have been performed. Therefore, proper in-
A calibration certificate establishes links to applicable
stallation and calibration are critical to comply with
standards and proves compliance. For critical instru-
the standards.
ments, documentation demonstrating measurement
uncertainty under additional tolerance and safety fac-
How operator training impacts audits tors may be valuable. For its clients, METTLER TOLEDO
Installation includes unpacking, set-up, configuration, issues a Minimum Weight Certificate to establish bul-
calibration, adjustment, training – and documentation letproof documentation that helps in passing audits.
of all these actions. The manufacturer can install a

METTLER TOLEDO © 11/2016 - Quality Management 99

 5 Verifying Equipment Accuracy

Inappropriate use, accidental damage, changes in en- Regulations like ISO, GMP, and GFSI-based standards
vironment conditions or water ingress can alter instru- remain silent on determining these parameters. Here
Quality Management

ment accuracy. Since calibration is normally only car- again, concepts developed under the GWP® guideline
ried out once or twice per year, users typically perform work.
process-specific verifications between formal service
visits themselves. Test frequency should be determined by risk level
and process tolerance, as depicted in the following
Users determine which tests to perform, taking into ac- diagram.
count process risks and tolerances. Ideally, this means
establishing:
• A test list (sensitivity, repeatability, eccentricity)
• Testing frequency
• Weights used
• SOPs to be followed for the tests
• Test weight verification/recalibration frequency
• Verification of tolerance, control and warning limits

0.01%

0.1%
Weighing k
Accuracy r Ris ting
1% he Tes
Hig ore
10% =M

Impact
Low Medium High

If a measurement mistake has no impact on the pro- • appeal to instrument functions and self-tests, or
cess (low risk) and required tolerance is wide (>10%), • use weights to perform simplified routine testing.
there is almost no need for verification. Conversely, if a
mistake would impact consumer health (high risk) Verification tests only work if an operator can obtain
and process accuracy has a narrow tolerance appropriate weights. METTLER TOLEDO has developed
(<0.1%), a verification procedure with higher frequency two-weight sets called CarePacs, which are sufficient
is necessary. More risk plus stricter tolerance equals to conduct all tests required to ensure scale accuracy
higher testing frequency. called CarePacs and can also supply high-quality ref-
erence weights for testing any capacity scale. Because
Service technician calibration is the only method to es- a larger and more expensive weight set is not required,
tablish national and international standards compli- the initial investment is reduced. Costs associated with
ance and also determines measurement uncertainty maintenance and recalibration are lowered as well.
so that it can be confirmed that process tolerances
can be achieved. However, to determine if an instru- METTLER TOLEDO can assist with the appropriate
ment will satisfy process tolerance on a daily basis, combination of tests as well as the selection of test
an operator can: weights themselves.

100 METTLER TOLEDO © 11/2016 - Quality Management

 6 Summary

Efficient quality management helps increase productiv- Service technician calibration establishes national and
ity and reduces costs. Choosing the right weighing international standards compliance. However, routine
Quality Management

system, establishing testing frequency based on risk self-testing on an established schedule can help with
and tolerance, and training internal personnel to spot- regulatory compliance and improve day-to-day opera-
check accuracy can help a manufacturer pass re- tions. If weighing mistakes are low-risk and tolerance
quired audits, assure quality and keep rejects – or is wide, verification needs are few. However, if issues
worse, recalls – to a minimum. such as company reputation or consumer health are
at stake, higher testing frequency is required.
Establishing characteristics such as weighing range,
smallest net weight, process tolerance and safety mar- Testing costs and operator experience are integrated
gin helps guide weighing system selection. Other im- into METTLER TOLEDO’s Good Weighing Practice™
portant concerns include ingress protection, explosion/ (GWP®), a reality-based weighing practice model that
corrosion protection, hygiene and connectivity. can be applied in any scenario in which accurate
weighing is crucial to product quality and safety.

7 Additional Resources

• For more information about Good Weighing • For more information about CarePacs® and their
Practice™, risk evaluation or effective scale role in establishing cost-effective, highly accurate
operation, log onto scale testing practices, visit
www.mt.com/gwp www.mt.com/carepacs

Mettler-Toledo GmbH
Industrial Division
www.mt.com/ind-food-guides
CH-8606 Nänikon, Switzerland For more information
Tel. + 41 44 944 22 11

Local contact: www.mt.com/contacts

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
MTSI 30364121 / Marcom Industrial
101
 For your Notes
Notes

102
 For your Notes
Notes

103
 www.mt.com/ind-food-guides
For more information

Mettler-Toledo GmbH
Industrial Division
CH-8606 Nänikon, Switzerland

Local contact: www.mt.com/contacts

Subject to technical changes

© 12/2016 Mettler-Toledo GmbH
MTSI 44098014