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Bakery, Snacks & Sweets

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Industrial weighing and measuring


Complete Quality Control SystemA Solution for Filling for the Food Industry

Filling containers requires very fast, precise and repeatable results. Inconsistency in

weighing can be costly – either giving away product by overfilling containers or risking

fines by not meeting Weights and Measures standards or net weight legislations.

A large US pudding and yogurt manufacturer was facing this exact problem monitoring

their fill weights during packaging.

Fill weights were inconsistent and fill-er operators were not performing theStatisticalQualityControl(SQC)processcorrectly.Thecustomerneededamethodbywhichtheycouldmonitorfillweightsand attributes such as product appear-ance, labeling, and expiration date ona real-time basis enabling immediateadjustments to be made to their proc-esseswhenrequired.

METTLER TOLEDO fills in the gaps Afterhearingaboutthecustomer’sproblem,METTLERTOLEDOperformedasite-studytofindoutexactlywhereinefficiencieswereoccurring.Anequipmentspecificationandrecommendationwasdeliveredtothecus-tomershortlyafterthevisit.BothMETTLERTOLEDOandthecustomerdeterminedthat

theprojectcouldbedeliveredintwophasesovera6monthperiod.DuringPhaseIoftheproject,thecustomerinstalledasin-gle stationconsistingofone ID30–anindustrial PC weighing terminal and aKA15s weighing platform (15kg×0.1g)– a stainless steel, high-precision scalebasecapableofwithstandingwetwash-downenvironments.FreeWeigh.Net®theMETTLER TOLEDO Statistical QualityControlsoftwarewasinstalledsothecus-tomercouldtrackthefillingprocess.

Immediate adjustmentsFreeWeigh.Net® records and tracks netweightandotherqualitydatafromsam-plestakenofftheproductionline.Fromthesampledataitcalculatesproductionmean, range and standard deviation,whichisthebasisforqualityassessment.

METTLER TOLEDO Bakery, Snacks & Sweets News 72

Publisher Mettler-Toledo AG Industrial Heuwinkelstrasse CH-8606 Nänikon Switzerland Production MarCom Industrial CH-8606 Nänikon Switzerland Subject to technical changes © 07/2008 Mettler-Toledo AG Printed in Switzerland

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ForoperatorsandsupervisorsthisdataismadeavailableonlineonthePC-termi-nals.Thisdataiscrucialforimmediateadjustmentdecisionsandismadeavail-able to operators and supervisors on aPC-terminalattheproductionline.Theresult is much tighter control over theprocessanddrasticreductioninoverfill.

Configurablereportsaregeneratedauto-matically by FreeWeigh.Net® being thequality documentation of the producedbatches – without requiring additionaleffortbythecompany’spersonnel.

The system completely paid backThe customer noticed an immediatedifferenceininventory–andaftersixmonths thePhaseIsystemcompletelypaidforitselfbyreducingoverfillcosts.Basedonthesuccessofthefirstphase,the customer completed Phase II ofthe project by installing additionalequipmentintotheirfacility.Thefinalsystem includes four ID30 worksta-tions with KA15s weighing platformsand FreeWeigh.Net® software whichallows the manager to monitor thefilling process from a remote PC. Anattributes module was added to theFreeWeigh.Net® installation to trackother quality characteristics such asproduct appearance, labeling, andexpiration date in addition to netweight. After Phase II the companynowhasacompletequalitycontrolsys-tem. The package was secured with aMETTLERTOLEDO service agreementwhich includes regular calibrationsand standard maintenance checks toensurethattheequipmentcontinuestodelivergreatresults.

Fast facts: KA15s weighing platform

• Capacity: 15 kg• Resolution: 1g

Weights & Measures approved• Platform size:

280 × 350 mm• Full stainless steel• Load plate: AISI304,

optionally AISI316• IP67 protected

Key customer benefits of FreeWeigh.Net®:• Significant reduction of product

overfill cost• Compliance to legal fill requirements• Standardized and simplified processes• Online monitoring and alarming• Short reaction time in production• Automated reporting• Scalable system implementation

and enhancement• ERP integration• Fast ROI (<12 months)

Attributes and testplans module:

Input of product quality attributes from visual inspection and execution of Test-plans-linking individual measurements and checks together to a sequence.

• Ensures completeness of quality data• Simple operation• Graphical representation

Master stationSupervisor’s office

Ethe

rnet

Graphical representations and analysis of net content and other quality data

Configurable quality docmentation

Production Line 1

Production Line 2

Production Line 3

Production Line 4

METTLER TOLEDO Bakery, Snacks & Sweets News 7 3

The BBA221 is a scale for your routine applications in dry areas,

such as your receiving department or warehouse.

Bench and Mobile Weighing For Your Routine Applications in Dry Areas

Theterminalwithitslargedisplayisfastandeasytooperate.Thescaleoffersover/undercheckweighing,portioning,classi-fyingandcountingfunctions.ItfeaturesaRS232interfacetocoveryourdatacom-municationneeds.Furthermore,itispow-eredeitherby4-Csizebatteriesoroption-allybyarechargeablebatterypack,whichenablesthescaletobeusedflexiblyacrossthewholepremises.

Choosefromawiderangeofaccessories:rollertrack,ballplatter,standorwallfix-turefortheterminal.The500×650mmand600×800mmsizeweighbridgescanalso bemounted ona cart andused asmobilescales.

Easy to operateFor manual portioning or checkweigh-ing applications the BBA221 featuresa straightforward and easy to handlethreshold definition system. Activate theapplication by F functionkey, store thetargetweightaswellasthepredefinedtol-erancesandyouarereadytogo.Automatic taring allows operationwith-outpushingthetarebutton.Afterplacingtheemptycontainerontheweighingplat-form,theweightisautomaticallysavedasthe tareweight (net indicator appears),thisallowsfastandtime-savingoperationandalsoresultsinlessfailure.

The weight valueFor higher precision measurements theterminalfeaturesa×10function,whichdisplaysthereceivedvaluewithahigherresolution(×10)forapproximative20sec-onds(notWeights&Measuresapproved).

Over, ok, under indication for checkweighing, portioning

and classifying applications

BBA221 bench scaleFunctional design allowing easy, intuitive operation

Printing/transferring data

Key benefits and facts BBA221

• Easy to perform accurate checkweighing, portioning and classifying measurements

• Weighing range 6 to 300 kg or 13.5–660 lb

• Max. Resolution: 30 000d, OIML 3000e NTEP 5000d

• Fast indication of the weighing result on the big LED display (< 1 s)

• High mobility due to integrated 4-C size batteries or optionally a rechargeable battery pack and cart

• Standard RS232 Interface• Rugged, painted carbon steel platform with 6 integrated overload stops• Optional: Stainless steel terminal

(IND226), internal rechargeable battery pack, cart, roller track, ball platter

Mobile weighing: IND221 with cart

×10 Function for higher resolution

Function key

Ball platter Roller track

Stands: carbon orstainless steel(300, 600, 900mm)

Unit switch indication


Sani

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Safety and integrity of your products is at the very heart of your brand’s reputation.

When sanitation practices are insufficient, bacteria can harbor and thrive in equip-

ment used in food processing. Also scales may harbor and transfer the bacteria to products.

When this occurs, scrupulous sanitation must occur to eliminate potential hazards.

Sanitary Equipment DesignFor Your Brand’s Reputation

Bothindustryandgovernmentareworkingdiligentlytoreducetheincidenceofbacte-ria’ssuchasListeriainfoodsandpreventitsgrowthandspreadinfoodprocessingplants.Equipmentisapotentialsourceofpathogengrowth–soisitthescale!Oneofthemostimportantfactorstoconsiderwhen buying scales for the use in foodprocessingaredesignandconstructionasrelatedtocleanabilityandthetypeofma-terialusedforconstruction.

Guidelines to evaluate cleanabilityThe American Meat Institute has es-tablished an Equipment Design TaskForce with the objective to minimizethe spread of Listeria in meat process-ing plants. This Task Force has es-tablished sanitary design principlesandcriteriainconsultationwithequip-ment manufacturers, certifying organi-zations and government officials. Thefollowing10principlesofsanitarydesignhavebeendeveloped.

1. Cleanabletoamicrobiologicallevel:Food equipmentmust be constructed toensureeffectiveandefficientcleaningoverthelifeoftheequipment.Theequipmentshouldbedesignedastopreventbacterialingress,survival,growthandreproductiononbothproductandnon-productcontactsurfacesoftheequipment.

2. Madeofcompatiblematerials:Con-struction materials used for equipmentmust be completely compatiblewith theproduct,environment,cleaningandsani-tizingchemicalsandthemethodsofclean-ingandsanitation.

3. Accessible for inspection, mainte-nance,cleaningandsanitation:Allpartsoftheequipmentshallbereadilyaccessi-bleforinspection,maintenance,cleaningandsanitationwithouttheuseoftools.

4. Noproductorliquidcollection:Equip-mentshouldbeself-drainingtoassurethat

liquid,whichcanharborandpromotethegrowthofbacteria,doesnotaccumulate,poolorcondenseontheequipment.

5. Hollowareas of equipment suchasframes and rollers must be eliminatedwhereverpossibleorpermanentlysealed.Bolts, studs, mounting plates, brackets,junction boxes, nameplates, end caps,sleevesandothersuchitemsmustbecon-tinuously welded to the surface not at-tachedviadrilledandtappedholes.

6. Noniches: Equipment parts shouldbefreeofnichessuchaspits,cracks,cor-rosion, recesses, open seams, gaps, lapseams,protrudingledges,insidethreads,boltrivetsanddeadends.

7. Sanitary operational performance:Duringnormaloperations,theequipmentmustperformsoitdoesnotcontributetounsanitary conditions or the harborageandgrowthofbacteria.

Your benefits

• Reduce biological and chemical contamination risks• Fast and thorough cleaning procedures• Fulfillment of hygiene regulations• Long equipment life due to rugged design

Open, easy-to-clean construction with no hidden holes

Hermetically sealed loadcells,IP68 for prolonged submersion andIP69k for high pressure washdown

Minimal horizontal surfaces avoiding remaining water (bacteria)

PBA430 bench scale


Simple Weighing

Filling/Dosing

Batching/Blending

Fomulation/Recipe

Inventory Management

Inbound/Outbound Vehicle Weighing

SQC/SPC/Quality Assurance

Over/Under Checkweighing

In-Line Checkweighing

Mobile Weighing

Customer Specific

Water ingress protection up to IP69k

Closed, easy-to-clean back of the stand,no visible cable

Smooth surface (RA < 0.8 μm) for trouble-free cleaning

No open threads

No product can remain

Full AISI 304 stainless steel constructions, optional AISI 316 load plates

BBA4x9 combi scale

NSF: National Sanitation Foundation

American non-profit and non-governmental organization. It is the wold’s leading organization in – standards development, – product certification, – education, and – risk-management for public health and safety.

EHEDG: European Hygienic Engineering and Design Group

Consortium of – food manufacturers, – equipment manufacturers, – research institutes and – public health authorities, with the aim to promote hygiene during processing and packaging of food products.

Sanitary scales and terminals:

IP68 IP69k EHEDG NSF GMP Applications

Floor scale PUA579 • • •Bench scale PBA430 • • • • •Combi scale BBA4x9 • • • •Terminal IND4x9 • • • •Terminal IND690 • • • •Terminal IND780 •PC terminal ID30 • •

8. Hygienic design of maintenanceenclosures:Maintenance enclosures andhumanmachineinterfacessuchaspushbuttons, valve handles, switches andtouchscreens,mustbedesigned,toensurefoodproduct,waterorproductliquiddoesnotpenetrateoraccumulateinandontheenclosureor interface.Also,physicalde-signoftheenclosuresshouldbeslopedorpitchedtoavoiduseasstoragearea.

9. Hygienic compatibility with otherplant systems: Equipment design mustensurehygienic compatibilitywith otherequipmentandsystems,suchaselectrical,hydraulics,steam,airandwater.

10. Validatedcleaningandsanitizingpro-tocols:Proceduresforcleaningandsanita-tionmustbeclearlywritten,designedandproven effective and efficient. Chemicalsrecommendedforcleaningandsanitationmust be compatiblewith the equipmentandthemanufacturingenvironment.

Source: AMI Fact Sheet:

Sanitary Equipment Design,

Amercian Meat Institute, March 2007

Sanitary scales METTLERTOLEDOhas seriously takentheseguidelinesintoaccount.Construct-edafterthelatesthygienicdesignguide-linesofNSFandEHEDG,ourscaleswith-standharshestcleaningproceduressuchassubmersion(IP68)andhighpressurecleaning (IP69k). Profit from hygieni-callydesignedscalesallowingthoroughlyandefficientcleaning!

www.mt.com/ind-hygienic-design

Protected against submersion

Dustproof and suitablefor cleaning with high-pressure equipment


Vehi

cle

Scal

es Reliable Vehicle Weighing with MTX Load Cells

With more than 600 000 in service worldwide, POWERCELL® MTX® load

cells have a proven history of accurate and reliable performance

in the toughest environments.

The MTX load cell uses provenPOWERCELLtechnologythatprovidestheultimate inweighing for trucksand railcars. Inaddition toweighingaccuratelyinall types of climates, it operates reli-ablyoveralongservicelife.Theresultisaheavy-capacityloadcellthatdeliversthebestvalueforyourmoneybymeetingthereal-worlddemandsofvehicleweighing.

ReliabilityEveryminutethatascaleisnotabletoop-eratemeans lost revenue.MTXloadcellsaredesignedtokeepyourscalerunningbypreventingproblemsandbyhelpingtosolvethemiftheydooccur:

• SolidConstruction–Thedurablestain-lesssteelloadcellperformsinthetough-estenvironments.Itishermeticallysealedtoprotecttheinternalelectroniccompo-nents fromdamage inwetor corrosiveconditions.Thewater-tightenclosureisratedIP68/69ktowithstandcontinuousimmersionandpowerwashing.

• DebrisProtection–Apliablebootkeepsdustanddebrisfromcollectingaroundthe loadpin.Thatallows the loadpintomovefreely,helpingtomaintainthescale’sweighingaccuracy.

• LightningProtection–Theloadcellhasbuilt-in transient voltage suppressorsthatprotectagainstcostlydamageduetolightningstrikesandpowersurges.It

isakeypartofourfour-stagelightningprotection system,whichalso includesdouble-shielded cables, current-block-ing junctionboxes, anda single-pointgroundingkit.Thesystemwastestedbyanindependentlaboratorytosimulatea10000-amplightningstrike.

• Self-Diagnostics–Each load cell cal-culatesandtransmitsaweight15timespersecond.Ifthereisaweighingerror,theloadcellnotifiesthescaleoperatorinstantly,allowingmaintenanceperson-neltopinpointtheproblemandgetthescalebackinservicequickly.

Exceptional valueWhenselectingaloadcell,consideritsto-tal cost of ownership. Inaddition to theinitialpurchaseprice,factorinthecostofdowntime,maintenance,service,andlostinventory.Anyinitialsavingsfrombuyingeconomyloadcellsareeatenupbythein-creased cost ofupkeep.Byproviding themost reliableheavy-capacityweighing intheindustry,MTXloadcellsgiveyouthebestvalueoverthelifeofyourscale.

www.mt.com/vehicle

MTX® POWERCELL® Load Cell

17-4 PH precipitation-hardened stainless steel receiver

hermetically sealed enclosure

Debris-protection boot

Built-in lightning protection and self diagnostic capabilities

Corrosion-resistant polished 304 stainless steel

17-4 PH stainless steel load pin

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A Garvens S series CombiChecker was installed in addition to the VS checkweigher

SAFELINE X-ray machine inspecting foil wrapped cakes


Kuchenmeister Ensures High Quality Standardswith Product Inspection Equipment

To achieve optimal production processes and a consistent, high quality

product, Kuchenmeister uses a range of product inspection equipment

from METTLER TOLEDO, including GARVENS dynamic checkweighers and

Safeline metal detection and X-ray inspection systems.

Kuchenmeister, a family-owned bakery,hasbeenproducingarangeofbakeryspe-cialitiesforover120years.ThecompanyaremarketleadersincakesandareoneofthelargestbakeriesinGermany,distribut-ingover500productsworldwide,undertheirownandretailerbrandnames.

“Toensurethehighqualityofourproductswehavetoworkinstrictaccordancewithourrecipes,”explainsDr.Zurhelle,HeadofQualityAssurance.“Wehavehighstand-ardsregardingthequalityandtasteofourproducts.”The computer controlledpro-ductionequipmentincombinationwiththelatestmachinesandstate-of-the-arttech-nologyensureoptimisedproductprocessesandconsistent,highqualityproducts.

METTLER TOLEDO Garvens installed aCombiChecker to ensure the quality of

theirMilkyWaycroissants.ThismachinecombinesanSSeriescheckweigherandametaldetector,ensuringproductsarenotonlyproducedtotherequiredweightbutare free frommetal contamination. 210productscanbeweighedperminuteatanaccuracyofupto300mg.Productsthatdonotmeetthesestandardsareautomaticallyrejected,inaccordancewithstrictIFSandWeightsandMeasuresqualitycriteria.

Kuchenmeister’s foil wrapped cakes areinspected using METTLER TOLEDOSafeline’s X-ray machines which detectand reject products with contamina-tion, missing content or those incor-rectlysealed.Despitethemetallizedfilmpackaging,theX-raysystemcandetectarangeof contaminantsoftenoriginatingfrom the farmers field, gathered inwiththerawingredients.

Through METTLER TOLEDO Garvensservice support which offers competentadvice, on-site operator training andverificationpackages,Kuchenmeistercanbe confident they can relyonMETTLERTOLEDO to ensure optimum productionprocesses, high uptime and consistenthighqualityproducts.

www.mt.com/pi

2

GARVENS

SAFELINE

Breadth of experience, depth of capability

21 43

1

3

www.mt.com/ind-bakery-snacks-sweetsFor more information

Mettler-Toledo AGCH-8606 GreifenseeSwitzerlandTel. + 41 44 944 22 11Fax + 41 44 944 30 60

Your METTLER TOLEDO contact:



1.Washdownnetcontentcontrol:IND469rem/KA3s2.HalogenMoistureAnalyzers3.Floorscalefordustyandhumidareas:PFA575

Brochures/Catalogs:1.StatisticalQualityControl/StatisticalProcessControlBrochure2.FoodandBeveragesBrochure3.IndustrialWeighingCatalog20084.ProductInspectionSolutions

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