classifying and quality control automated, fast and efficient · classifying and quality control...

News2Industrial

Industrial Weighing and Measuring

0.5 seconds per stemmaximizes throughput Productivity is of major importance for banana producers in Ecuador. Approxi-mately 4000 banana stems weighing 140 000 kg go through a mid-sized check-ing station daily.

The Bana-Scale is connected to an analog weighing bridge that dynamically weighs 100 % of the banana stems harvested. With the IND780 terminal’s fast scale A/D up-date rate, advanced filtering technology and multi-tasking processor, the system is able to weigh accurately up to speeds of 0.5 seconds per stem. This helps to maxi-mize production throughput.

Espinosa Páez S.A. has long been serv-ing the needs of major banana producers in Ecuador with their Bana-Scale system solution. The Bana-Scale helps users to quickly and accurately weigh, classify and collect quality related data on the various types of bananas produced.

The system had originally incorporated the METTLER TOLEDO JagXtreme® terminal with custom JagBasic programming. While the JagXtreme® has reliably performed throughout the years, its successor the IND780 terminal brings even more power and flexibility into the system to meet the ongoing customer demands for automa-tion and productivity improvements.

Classifying and Quality Control Automated, Fast and Efficient

Being one of the top banana exporters in the world with a 30 % share, Ecuador has

strived to elevate their banana industry to the highest quality level, assuring a

year-round supply of bananas to the Global market. METTLER TOLEDO and its partner

Espinosa Páez S.A. have provided an innovative solution to serve the quality

system requirements of Ecuadorian banana producers and exporters.

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PublisherMettler-Toledo AGIndustrialHeuwinkelstrasseCH-8606 NänikonSwitzerland

ProductionMarCom IndustrialCH-8606 NänikonSwitzerland

Subject to technical changes© 07/2008 Mettler-Toledo AGPrinted in Switzerland

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0 Effective production and quality control managementDuring the production process, many dif-ferent types of bananas are checked and classified based on their weight, color and quality. The Bana-Scale system al-lows the operator to easily capture all the necessary information to facilitate the classification process. To monitor the production, weight to-tals are automatically accumulated and assessed for the day, color code, lot and cable numbers. Furthermore totals are generated for each individual harvesting crew and this data is used to calculate the wages for the crew members.

Rejection reasons and weight totals for re-jected stems are also captured to assist the user in their quality analysis and to rectify problem areas. Operators are also required to capture sample data on other quality measurements such as the calibration of the second and last hands of a stem, finger lengths and number of hands.

User friendly operator interfaceIND780 comes with a bright 145 mm QVGA graphical LCD display available in monochrome or Active TFT Color. Opera-tors can appreciate the clear and intuitive on-screen view of the process status while it is running. Large pushbuttons, help in-structions and local language operation are provided by the system. As a result,

minimal training is required to operate the system without errors.

Customizable platform for full operational flexibilityUtilizing the IND780 terminal’s new and improved programmable platform Task-Expert™, Espinosa Páez S.A. is able to develop a solution customized to the end users’ needs. Making modifications to a program is made easy with the flow chart based TaskExpert development tool.The true multi-tasking architecture al-lows TaskExpert programs to be ex-ecuted simultaneously. The dynamic weighing process can be running in the background while the operator performs reporting tasks or data entry saving precious operation time.

Efficient on-line data management and accessibilityIND780 provides a built-in SQL CE da-tabase that allows easy data storage and report generation on the production pro-cess. Different combinations of data can be easily compiled and reported based on fields such as the date, lot, cables and color code as an advantage of the relational database structure.

With up to 200 MB of flash memory, long term records are stored and can be re-trieved as historical data or accumulated for a historical analysis.Reports are generated on a printer po-sitioned at the production line for the operator’s convenience. Supervisors and production manager retrieve their reports at a PC connected to the system via Eth-ernet TCP/IP.

This ease of data management and acces-sibility improves evaluation of the banana plantation’s operational performance and gives traceability of the processes.

IND780 monitoring screens with on-screen view of the process status

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Optimizing capsule counting accuracy

METTLER TOLEDO was approached by a leading gelatin capsule

manufacturer to optimize their capsule counting system.

In addition to their expertise in hard gela-tin capsules, our customer offers a new range of soft gel capsules available in a wide variety of shapes, sizes and colors, suitable for oral, topical or ophthalmic administration.

Manufacturing such products requires cutting-edge production facilities. Hence our customer’s engineering department called upon METTLER TOLEDO to design a pilot capsule bag filling solution.

METTLER TOLEDO has already supplied this production site with several weighing solutions. As seen in the picture oppo-site the site has weigh booths contain-ing weigh scales connected to an IND690 terminal. These are for the weighing of active ingredients and excipients in the formulation of the capsules. Each booth contains three different sized scales to al-low for the dispensing of small, medium or large volumes. Each IND690 terminal is in turn connected to a bar code reader to ensure the correct ingredients are used and a label maker to print labels for the finished weighed material.

Innovation at the heart of the manufacturing processThe subsequent collaborative development of an innovative weighing solution brought about a significant improvement in weighing precision. METTLER TOLEDO’s expertise in the pharmaceutical, cos-metic and food additives industries – the markets served by our customer, was a key factor in our success.

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IND780 monitoring screens with on-screen view of the process status


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IND690• Up to four scales/balances

connectable• Water and dust-proof• Wide variety of software Pacs

such as Count, Form, Com, Sum, Fill, Batch, Control, FormXP

• Broad interface range available: Ethernet, WLAN, USB, Bluetooth, Profibus® DP

• Material identification through barcode reader and RFID

Barcode reader

K-Line precision bench scale: KB60s• Stainless steel platform, IP67• Capacity to 60 kg• Readability 1 g• Typical minimum weight: 80 g (for 1 % tolerance)

DN floor scale: DNO 600sk • Stainless Steel Platform, IP68• Capacity to 600 kg• Resolution of 2× 3000e multi-range• Readability 100 g/200 g

K-Line precision bench scale: KA15s• Stainless steel platform, IP67• Capacity to 15 kg• Readability 0.1 g• Typical minimum weight: 10 g (for 1 % tolerance)

GA46 printer

Total formulation control

The capsule bag filling system

IND690 indicator


Carriers have a system to ensure that they are paid properly for the space parcels

occupy on their trucks and airplanes. If you’re only using weight to determine

freight costs you could be hit with unexpected back charges. Accurate parcel volume

is the key to mastering your shipping costs.

Serum Institute of India Ltd. is an ex-port-orientated business and as an official vendor for the World Health Organisation, ships hundreds of thousands of packages each week around the world.

Although Serum Institute had predefined box sizes, the actual dimensions of the packed boxes varied to the point that the company was receiving back charges from their car-rier for failing to report accurate package Dimensional Weight. The high volume of shipments meant that manually measuring each box was inefficient and unreliable.

Due to these escalating costs, the com-pany turned to the expertise of METTLER TOLEDO who explained how the major car-riers use Dimensional Weight to calculate shipping costs, and how this can result in

unwanted back charges. Subsequently, a visit to the company’s freight forwarder was arranged and top management from the company were given a live demonstration of how METTLER TOLEDO’s dimensioning system, the CS5400 BarCoded YardStick™ can be used to accurately calculate Dimen-sional Weight.

The company immediately saw the benefits of using the CS5400 in their warehouse opera-tions for capturing accurate package volume and weight. The CS5400 now plays a major role in the packaging department, enabling them to accurately report the Dimensional Weight of their outgoing shipments to their carrier. Since investing in the dimensioning system, back charges are a thing of the past.

www.mt.com/dimensioning

Serum Institute of India Ltd. Masters Back Charges

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About Serum Institute of India Ltd.

Founded in 1966, Serum Institute of India Ltd. is the world’s largest producer of Measles and DTP group of vaccines. It is estimated that two out of every three children immunized in the world are vaccinated with their products. The company’s products are now used in 140 different countries around the globe and their core philosophy is to make their vaccines affordable to everybody.

CS5400 BarCoded YardStick™

Description Automatically measures the dimensions of objects and quickly and reliably sends the information to your host com-puter system. This provides the means to improve warehouse planning and shipping cost management procedures.

Throughput Up to 200 parcels per hour

Specially developed software MT Pack software developed by METTLER TOLEDO for Serum Instituteof India Ltd. has the ability to store dimensions of an order and use infor-mation as a reference for calculating the dim weight of other boxes of a similar size.

Facts about the location Predefined box sizes: 60 × 48 × 41 cm60–70 parcels per hour1 sorting lineStatic conveyor line, processes are pushed by hand

CS5400Measurement Platform

Label printerPlatform/bench scale

Bar code reader

Industrial PC with 12“ TFTmonitor and keyboard andCSM application software

Communication to host WMS or ERP


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Vertex floor scales are versatile enough to be installed on top of the floor, in a pit, or used as a portable scale. Top-of-floor installations can be equipped with ramps to make them easily accessible from all four sides. Pit installations use our

Do You Worry About Side Shocks?Rely on Rocker Pin Suspensions

The 2158 VERTEX low profile floor scale is designed for tough industrial environments such as

accidental overload by fork trucks. They can handle 100% end loading, making them ideal

for use with concentrated loading applications. It saves installation cost because suspension,

bumpers and overload stops don’t need adjustment.

These floor scales are ideal for concentrat-ed-loading applications such as bins, carts, and forklifts. They are designed to withstand the conditions common to shipping hubs. Components do not become loose or out of specification and maintain their weighing ac-curacy and repeatability even after years of heavy use.

Quick-Pit frames, which ensure a perfect installation that is flush with the floor. The scales can be made easily portable by equipping them with forklift channels for easy lifting or with a wheel kit.

Overload protection stop prevents damage to the load cell. It never needs adjustment.

Fixed end and sidebumpers protect load cells from side-loading damage. It never needs adjustment.

Hermetically sealed stain-less steel load cells to keep

out moisture and dirt.

Rocker Pin is self-aligning and self-centering. Only vertical forces are transmitted to the load cell. The pin is well integrated and doesn’t come off like

other solutions if the scale is hit by side shocks.


Statistical Quality Control –Highest Precision for Hygienically Sensitive Areas

Special measuring instruments are needed for quality control in environments with strict hygiene require-

ments. With the network-capable IND469rem terminal and the KA3s/KA6s scales, METTLER TOLEDO

has the ideal weighing system for connection to the FreeWeigh.Net® quality control software. These devic-

es are made of stainless steel and are a great way to meet high-precision and strict hygiene requirements.

FreeWeigh.Net® – Quality control in a networkMore and more customers are demanding networked quality control for their prod-ucts, i.e. central monitoring and evalua-tion of filling quantities as well as other import quality attributes. With its PC-based FreeWeigh.Net® Statistical Quality Control system, METTLER TOLEDO offers an ef-ficient solution for this demanding task. And when the IND469 terminal is coupled with the KA3s or KA6s platforms, this offers quality control in wet areas.

Maximum IP protection and simple cleaningThe IND469rem terminal has been de-signed to comply with the latest EHEDG and NSF hygiene design guidelines and is therefore ideally suited for use in wet areas. It is both dustproof and waterproof in line with IP69k (DIN40050) and its extremely fine stainless steel surface (Ra <0.8µm) makes it a breeze to clean.

Network connection is hygienic and saves costsThe terminal is connected to the FreeWeigh.Net® network via an Ethernet interface or simply and cheaply without the need for cables via WLAN.

Properties IND469rem and KA3s/KA6s

• Integrated remote application for network operation with FreeWeigh.Net®

• For monitoring finished packs with net filling quantities of: 5g–3000g (KA3s: 0.1g Weights and Measures approved) 10g–6000g (KA6s: 0.2g Weights and Measures approved)

• Stainless steel housing

• Waterproof and dustproof IND469rem: in line with IP69k KA3s/KA6s: in line with IP66/IP67

• RS232, PS/2, Ethernet or WLAN connection

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In order to meet commitments as the largest producer investor of the

nearby ethanol facility in Laddonia, Missouri, Carl Ehrlich, owner of

the CE Grain Company, LLC, decided to build a grain depot to receive and

ship corn as efficiently as possible.

Efficient Dump Through Truck ScaleHandling All In and Outbound Goods

The facility, which started operation in November 2006, is capable of storing over 360 000 bushels (9000 tons) of corn at peak capacity and has the potential for expansion to over 2 million (50 000 tons). Corn from area farmers is purchased at market prices and stored for delivery to the ethanol plant.

Like all business owners, two of Carl’s objectives in running this operation are efficiency and accuracy. METTLER TOLEDO is able to help meet these objectives by pro-viding a steel deck dump through truck scale to handle all in and outbound prod-uct. The scale is above ground and features steel grating around the entire width of the scale through which grain can be dumped through to the hopper below. The hopper is capable of holding 1200 bushels (30 tons) of corn and uptake to silos is rated at 5000 bushels/hour (125 tons/h).

One scale for in and outbound productsEfficiency is achieved in the weighing proc-ess – Trucks delivering corn enter the site and drive onto the scale. After a corn sam-ple is analyzed and gross weight taken the truck driver opens the belly dump trailer doors and corn is deposited through the scale grating into a hopper from where it is transferred to the silos. A second weight reading is taken of the empty truck/trail-er and a weigh ticket printed. The time between weighments (weigh full, dump grain, weigh empty) in considerably shorter than other dumping/weighing methods. Trucks picking up corn follow a similar procedure – Drive onto the scale, weigh empty, two overhead loadout bins fill the trailer and a full weight reading is taken. Both sequences are much more efficient than weighing in, driving to a dump area and weighing out.

Precise and reliable weighing technologyAccuracy, and repeatability are achieved by using POWERCELL® MTX load cells in the scale and a JagXtreme® scale terminal for weight data feeds to the site computer sys-tem. A driver display was also incorporated to view weight readings.

Carl has automated the site so that he can monitor and control loadout and corn moisture content in the silos from a remote location.

The scale was purchased from the area’s METTLER TOLEDO distributor Hammel Scale who also performed the installation and provides service to ensure the scale continues to provide accurate operation.

Carl is very pleased with the scale and the efficiency it helps provide to this operation.

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Fast facts POWERCELL® MTX

• 25t, 45t and 90t load cell, > 1000t scale capacity

• 3000e–6000e OIML, 5000e–10 000e NTEP worldwide approval

• Tested and proven for prolonged submersion and high-pressure washing (IP68/IP69k)

• Integral lightning protection• More than 500 000 in worldwide use• Instant failure notification• Digital closed loop correction of: – Temperature influence – Zero change – Hysteresis/linearity – Weighbridge creep – Vibration

• TraxEMT™ (Embedded Maintenance Technician) monitors: – Individual cell overload – Scale overload-shock – Number of cycles – Symmetry and drift

Full width scale grating provides large surface area for fast grain dump

Large driver display


Plastkov a.s. in Liberec, Czech Republic uses a high-precision MonoBloc scale from METTLER TOLEDO

as a fast and economical testing device. The scale is used to efficiently check that

modules consisting of several parts for customers in the automotive industry are complete.

Customer Benefit:

Missing part detection. Fast and reliable, even if it is very small

Saves money and engineering time to develop dedicated test devices

Easy calibration and traceability of the testing device to comply with TS 16949 and ISO 9001

Complete documentation of all test results

Is the Assembled Module Complete?Are all Parts on Board?

Plastkov a.s. in Liberec, Czech Republic is a Tier 1 supplier of molded plastic parts and plastic modules consisting of several molded parts for car manufacturers. It is certified according to ISO/TS 16949:2000. Its cus-tomers don’t tolerate errors. The preassem-bled modules are directly delivered to the assembly line of its customers without any entry check. Faults at this stage can be very expensive for Plastkov and its customers. It would also result in a time-consuming com-plaint process, in which the supplier must

explain why the fault occurred and what measures are taken to avoid it in future.Therefore, Tier 1, 2 and 3 suppliers often have to check all parts before shipment. These quality control procedures and tests can require a lot of manpower. Design-ing and manufacturing of test devices to perform those tests are expensive and time consuming. Scales from METTLER TOLEDO are economical and fast testing devices. Calibration and its documenta-tion are much easier to perform for a scale

then for an optical or mechanical device. Each part tested can be documented with lot ID, date and time in using a printer or sending the data to a computer. The calibration of a scale is traceable to a na-tional standard.

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Plastkov a.s. is very satisfied with solutions from METTLER TOLEDO as they are accurate, solid and easy to adapt to its customers’ needs


IND560fill – the Weighing Terminal for Smart Filling and Blending Applications

With the IND560fill you can quickly configure filling and blending applica-tions for up to four components, without complex and costly programming. The InSite™ software tool makes configura-tion easy and even allows you to simply copy configurations from one terminal to the next.

Standard and customizablefilling/blending sequencesThe Fill-560 application module adds advanced features to the standard tar-get control capabilities of the IND560 weighing terminal. This is accomplished through the addition of a hardware key that provides new setup parameters, se-quences, and input and output control for both the weigh-in cycle and weigh-out cycle. Fill with one material or blend up to four materials in the weigh-in cy-cle. Dump the entire contents or dose out

The IND560fill process weighing terminal is capable of solving both basic and

semi-complex filling and blending applications. It features standard

and customizable filling sequences configurable to your specific needs.

Fast facts InSite™ configuration software tool

• Online configuration: View and/or change real-time configuration of connected terminal from remote PC

• Offline configuration: Perform device-free configuration work before hardware installation

• Save configuration information locally on the PC for future use

• Load a saved configuration file into other terminals• Restore configuration to a known state for service purposes• One tool for multiple models: supports IND130, IND135,

IND560, IND560x, IND780 weighing terminals

Your benefits• Accurate, high-speed filling in harsh environments (IP69k)• Easy configuration of standard and custom

filling/blending sequences• Direct control of valves and feeders to eliminate a PLC• Easy to install, connect, and operate• Broad range of sensors –

8 load cells or platforms from < 0.1 g up to tons

multiple times into containers for the weigh-out cycle.

Save money with advanced controlValves and feeders can be directly con-trolled from the IND560fill, eliminating the need for a costly PLC. Discrete inputs provide sequence control from local or re-mote locations. The SmartTrac™ graph-ical display provides visual guidance for target weight and tolerances.

Fast filling: 366 updates/sec Filling and blending applications need speed. The extremely high A/D conver-sion rate of 366 readings per second is combined with proven TraxDSP™ fil-tering to make sure that you get fast, accurate weight information for target comparison. TraxDSP™ is a patented filter design that practically eliminates environmental noise and vibration to provide stable weights. The fast update rate keeps pace with your process speed, making it ideal for mixing, agitating or dynamic processes.

Weigh-in / weigh-outsequences

• Fill• Fill/Dump• Fill/Dose• Dose• Blend• Blend/Dump• Blend/Dose

Blend/DoseFill/Dump

For more informationwww.mt.com

Your METTLER TOLEDO contact:

USAMettler-Toledo, Inc.1900 Polaris ParkwayColumbus, OH, 43240Tel. (1) 800 523 5123

CanadaMettler-Toledo, Inc. 2915 Argentia Road, Unit 6Mississauga, Ontario, L5N 8G6Tel. (1) 905 821 4200

Mettler-Toledo AGSales InternationalCH-8606 GreifenseeSwitzerlandTel. + 41 44 944 22 11

1. Wash down net content control: IND469rem/KA3s2. Vehicle weighing terminal and load cells3. Floor scale for dusty and humid areas: PFA5754. In-line pH and turbidity sensors

A Wide Range of Solutionsto Improve Processes

Brochures/Catalogs:1. Brochure: Process weighing2. Brochure: Predictive Maintenance3. Industrial Weighing Catalog 2007

Share our KnowledgeLearn from our specialists – our knowledge and experience are at your

disposal in print or online.

Learn more about all of our solutions for the bakery, snacks and sweets industry at our website. You can find information on a wide range of topics to improve your

processes, including case studies, applica-tion stories, return-on investment calcula-tors, plus all the product information you need to make an informed decision.

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