field proven and patented.. the strategy to stay competitive, manufacturing companies must: increase...

Field Proven and Patented.

The Strategy

To stay competitive, manufacturing companies must:

• Increase speed of production

• Improve levels of quality

• Lower costs

The Targets

Key Manufacturing Areas:Production & Packaging

Key Process Phases:Material Transfers

Key Processes:Batching & Filling

The Goal

Transfer the exact amount of material, in the minimum

amount of time every

time !

The Current Status

Transfer the exact amount of material by lengthening the material transfer time every time.

Transfer the approximate amount of material in the minimum amount of time every time.

Case 1.

Case 2.

Or the Trade Off ...

The METTLER TOLEDO Q.i Strategy

• Take control of the material transfer phase

• Adapt to account for natural process variability

• Significantly impact:

- overall manufacturing efficiency

- manufacturing costs

- an enterprise's competitiveness.

The Application Markets and Manufacturing Areas

Manufacturing Areas

• Batching

• Blending

• FillingRaw Materials

• Granules

• Powders

• Liquids

• Slurries

Primary Markets • Food

• Beverage

• Chemical

• Specialty Chemical

• Pharmaceuticals

• Other

Video Overview

The Q.i Components

Software and Services

PAC Predictive Adaptive Control

Technology

A Manufacturing Company's Existing or

Proposed Process

Q.iMPACT Matrollers (Material Transfer

Controllers)

Q.iMPACT Matroller Overview

• Embedded with PAC technology

• Easily integrates with leading control systems

• Can be configured on a network to control a few or few hundred scales AND flow meters

Predictive Adaptive Control Technology Overview

• Builds real-time mathematical model of material transfer process

• Predicts exact moment of cutoff in current transfer

• Automatically compensates for process variations

Q.i365 Overview

• Production management tools

• Predictive/preventive diagnostics

• Internet-enabled software to monitor performance

• A team of METTLER TOLEDO experts available around the clock and around the globe to solve problems when needed.

How Q.i Integrates Into New or Existing Processes

Sample

The Benefits of the Q.i Strategy

Increases competitiveness. Grows profits.

Increases speed. Enhances use of investment capital.

Maximizes control. Improves quality.

Decreases waste. Reduces costs.

Measures performance. Drives improvement.

Increases Competitiveness. Grows Profits.

CASE STUDIES TRADITIONAL 2-SPEED

FEED

Q.i

1-SPEED FEED

SAVINGSIMPACT

(US$)

Case Study 1.•Increased Manufacturing Thoughput•Capital Spending Deferment

~120 mins/batch

~72.5 mins/batch

~$ 5 millionin 1 facility.

Case Study 2.•Improved Control•Reduction in Raw Material Usage

$ 4.91 overfeed per batch

$ 0.67 overfeed per batch

~$ 500,000per annumacross 11

batch systems

Case Study 3.•Reduction in Valves, Pipes & Controllers•Reduction in Maintenance Cost

2 Valves

2 Services

1 Valve

1 Service

~$ 90,000 less h/ware +$10,000 p/asaved over 9 material

paths

*These case studies illustrate actual results achieved by consumer goods manufacturers

Increases Speed. Enhances Use of Investment Capital.

Increases manufacturing throughput of batches by up to 30%.

Reduces cost by up to $10,000 per material delivery line.

Traditional Multi-speed

Material Transfer System

Single-speed, On-Off Material Transfer System

BRUTE FORCE Q.i

Maximizes Control. Improves Quality.

Repeatable Control* with

Previous System

Repeatable

Control* with Q.i

% Improvement

Recipe X Molasses 2.2 0.3 86.36

Recipe Y Water 0.11 0.067 62.77

Recipe Y Sugar 0.18 0.04 63.63

Recipe Y Flavor 1.44 0.04 97.22

Results from actual application by consumer goods manufacturer

*+/- % of full scale deflection

Decreases Waste. Reduces Costs.

Improved control tightens tolerances to a previously unattainable level.

Setpoints can be trimmed of the amount material required, reducing previous buffers.

0

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Weight in Kgs

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l tra

nsfe

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0

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Weight in Kgs

# o

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l tra

nsfe

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IDEAL SETPOINT

BUFFER SETPOINT

+ - TOLERANCES

Typical Control Method

Q.i (PAC) Control Method

Figure 1

Figure 2

Less Material Used = Less Waste = Reduced Costs

Measures Performance. Drives Improvement.

Measure performance and analyze

results

Learn, benchmark, improve, and sustain

peak performance

Around the clock and

around the globe

Global Q.i Team Headquarters (U.S)1-614-438-4390(For local contact numbers, visit www.mt.com)