process weighing

• Hardy delivers productivity solutions to manufacturers and processors

• Hardy developed the first PLC integrated weighing system

• We are a Rockwell Automation Global Encompass Partner

• We were founded as Hardy Scales in 1918

• Hardy is part of Roper Industries, a $2B+ public company

How to Develop Static/Dynamic Check Weighing Solutions using

off-the-shelf components from Rockwell Automation® and Hardy

Process Solutions. Overcome the Black Box, Green Board Problem!

Learn how manufacturers and OEMs in the food and consumer

packaged goods industries are improving product inspection capability

using off-the-shelf components to deliver amazing results. Components

include: PLCs and Human Machine Interface from Rockwell Automation

and high-speed check weighing bundles (instrument/sensor) from Hardy.

Agenda

1. Check Weighing

2. Business Needs

3. Solution & Case Study

Agenda

1. Check Weighing

2. Business Needs

3. Solution & Case Study

1. Many applications. Static and Dynamic.

SLICING BY CHECK WEIGHING

MULTI TRACK CHECK WEIGHING TARE & GROSS WEIGHT FILLING PUSH-OVER CHECK WEIGHING

SORTING BY CHECK WEIGHING

PUSH-UP CHECKWEIGHING

CATEGORIZATION BY CHECKWEIGHING

• Verify package contents

• Check product tolerance

• Classify product

•

• Identify parts

• Overload safety check

1. Many stand-alone check weighing solutions.

7

1. Many production requirements.

Agenda

1. Check Weighing

2. Business Needs

3. Solution & Case Study

2. The Problem

• Expensive “Green Board” Custom Hardware

• Software that is proprietary and/or obsolete

• Maintenance that can be unreliable.

2. What do manufacturers want?

• “Off-The-Shelf” technology. Also called “Open Source”

• Must meet specifications

• Must be reliable

• Above all the must be easy to integrate, use, modify and fix.

Agenda

1. Check Weighing

2. Business Needs

3. Solution & Case Study

3. Hardy & Check Weighing

3. Why are we different.

• Open-Architecture Platforms

– Non-black box solutions

– Direct RA Connectivity

• 3 levels of solutions

– Configured, Flexible, Packaged

• Service-Lite Technologies

– Hardy’s ToolBox makes it easier

An off-the-shelf solution

HI 4050CW

3. Hardy’s Solution – Product Overview

• Easy to Install, Use, Maintain & Change Lower. Cost Effective.

It’s not a black box, it is an off-the-shelf solution. It integrates to

Rockwell and other PLC’s.

• Up to 250 packs per minute

It breaks the traditional analog strain gauge “speed barrier”, without

the cost of MFR (Magnetic Force Restoration or Other similar high

speed/resolution technologies)

• Smart Features

It offers advanced EDGE DETECTION (weight on & weight off) and

operator indication of DATA QUALITY

3. Hardy’s Solution – Bundle Specifications (Controller)

3. Hardy’s Solution – Bundle Specifications (Loadcell)

Load Cell Capacities: 2, 5, 10 kg …up to 100kg

Load Cell Accuracy: Better than +- 0.015% of capacity

3. Hardy’s Solution – Working out the Solution

300g DYNAMIC ROLL TEST

2kg load cell

Vertical Axis in grams

Horizontal Axis 1 grad = 4 msecs

Settling time +- 256 mSec

Low Threshold 40g

High Threshold 280g

Motion Threshold 0.5g Variation Threshold 3g

THE LEDGE

Data Capture Starts

The case study outlines the NEEDS, OPERATIONAL

& FINANCIAL BENEFITS that Hardy’s 4050CW

check weighing bundle delivered to a global

Consumer Packaged Good manufacturer in the

Snack Food industrial market segment.

Customer Needs

• Meet speed spec (<400 msec/weigh)

• Meets resolution spec (<0.25g/weigh)

• Reduce product giveaway

• Uses know, open source technology

• Easy to use, modify & fix

• Retrofit into existing system

3. Hardy’s Solution – Case Study

EXISTING

LINE

LANE

DIVERTER

CHECK

WEIGHERS LANE REJECTOR

& CONSOLIDATOR

EXISTING

LINE

#1 #2 #3

3. Hardy’s Solution – example

MULTI TRACK CHECK WEIGHING

a) Reliability and lower life cycle costs. Accelerated ROI.

b) Reduction in Finished Product Give Away. Accelerated ROI.

3. Hardy’s Solution – Value Delivered

3. Hardy’s Solution – Meeting the Operation Outcomes

ROI - WHAT WAS THE “OPERATIONAL” VALUE ?

a) Reliability and lower life cycle costs. Accelerated ROI.

• Off the shelf components that are readily available and supported ongoing.

• Familiar components/technology that are well known.

• Component cost is considerably less than the current hardware components.

• Less dependence on vendor resources for upgrades, modifications, and troubleshooting.

• Components are robust and not subject to failure due to handling.

• Limited set of cost effective spares can be kept on-site

• Easier swap out of hardware

• Easier upload of software, configuration and calibration parameters dramatically reduces MTTR

(mean time to repair) in the event of a failure.

• Inter component communication via industry standard fieldbus protocols such as EthernetIP

• One HMI can display the production data for multiple rows

• The open platform allows for unlimited data collection and transfer to our MES system.

• Future loop control for weight control, and other controls enhancements are easily added.

• Depending on application: ROI can be reduced from years to months or months to weeks.

3. Hardy’s Solution – Case Study

ROI - WHAT WAS THE “DOLLAR” VALUE ?

b) Reduction in Finished Product Give Away. Accelerated ROI.

Estimated savings per portion = ~0.36% of finished product

Estimated savings = ~1$ Million in savings per month