Processors Invest in Automation Throughput to Increase by 14%

23News

Processed & Packaged Food

Changing retailer requirements, market growth and ever-increasing consumer requests

for product diversity are placing more pressures on processed and packaged food manu-

facturers. Enhancing productivity with improved weighing and inspection automation can

help packaged food processors to differentiate and compete in challenging markets.

Processors Invest in AutomationThroughput to Increase by 14%

There are different ways to overcome these obstacles.

Increasing OEEReviewing processes and upgrading or installing new equipment can signifi-cantly improve overall line effectiveness. The latest weighing and inspection solu-tions contribute to overall product quality improvements and higher levels of equip-ment availability and performance. These are the key metrics used to calculate OEE.

Optimizing manual processesNot all production processes can be auto-mated, but optimizing manual processes through better data integration can help with throughput. Manual checkweighing

Concerns and Industry challenges There has been a general concern among processed and packaged food processors that automation may lead to a loss of pro-cess control and overall quality, affecting their ability to comply with stringent stan-dards and regulations. In addition, man-ual processes and human skills can be difficult to automate.

A Food Engineering (FE) survey lists the following obstacles to productivity en-hancement: • Low Overall Equipment Effectiveness

(OEE) • Issues with process control and data

collection • Limited availability of factory floor

space

Industrial Weighing & Product Inspection

METTLER TOLEDO Processed & Packaged Food News 23

Proc

ess

Auto

mat

ion

& P

rodu

ctiv

ity

Publisher / ProductionMettler-Toledo GmbHIndustrial DivisionHeuwinkelstrasseCH-8606 NänikonSwitzerland

Subject to technical changes© 09/2017 Mettler-Toledo GmbH

Choosing the optimum weighing and in-spection solutions can significantly im-prove process automation. METTLER TOLEDO can support in analyzing pro-cesses and selecting the right solutions to improve productivity and efficiency.

www.mt.com/pi-pp

is labor intensive and can lead to opera-tor fatigue. Selecting a bench scale with smart data integration can be a first step towards a more automated process.

ICS bench scales can store article-related data including product name or target weight in the scale’s memory. With the help of an ergonomic workstation and in-creased data exchange, throughput can be improved by up to 25%.

Automated weighing and Inspection Many plants have the scope to fully au-tomate weighing and product inspec-tion. Dynamic checkweighers can be inte-grated into processing and packing lines

to weigh packaged product at high speeds. Out-of-specification products can be re-moved automatically without stopping the production line. Combination sys-tems with integrated metal detection an also check for physical contaminants in a single inspection unit with minimal floor space requirements. Advanced data collectionImprovements in automated process con-trol can be achieved using advanced pro-cess monitoring and data collection soft-ware. ProdX Inspect, FreeWeigh.net®

and Collect+TM software packages from METTLER TOLEDO enable food proces-sors to further benefit from automation.

2

Automated WeighingDynamic checkweighers can au-tomatically check every item and ensure consistency of package weights.

www.mt.com/checkweighing

Integrated Data CollectionProdX Inspect software simpli-fies the collection of process data from product inspection equip-ment to enhance productivity and support compliance.

www.mt.com/prodx-pp

New Industrial Weighing Catalog

Find Your Required Solutionwith Our Full Product Portfolio www.mt.com/ind-catalog-pp


Improve Filling Throughput Weigh Faster Than Ever

Speeding up automated weighing processes to an exceptional 600Hz allows 10 times faster fill-

ing. A new compact weighing transmitter provides full connectivity to PLCs and enables higher

throughput and improved productivity where valves and process are controlled by the PLC.

3

The new ACT350 weighing transmitter provides 600 filtered-weight values per second for fast weighing with an accuracy of 10,000 divisions according to OIML and NTEP standards. That enables fast and precise filling, sorting and batching pro-cesses, leading to increased throughput and profitability.

Designed for automationThe ACT350 is dedicated for use in auto-mation. Fieldbus connectivity via Ether-net/IP, ProfiNet® or Profibus® is incor-porated in a compact unit for DIN rail mounting. ACT350 fully supports PLC in-tegration with Device Description Files, making installation fast and easy.

Fast diagnostics An integrated display shows weight value. The same display can be used in combi-nation with the small keypad to get status information without any additional soft-ware tool or remote display.

Flexible calibrationACT350 supports accurate calibration with test weights. CalFree™ calibration is also supported if it is impossible to place test weights during calibration.

www.mt.com/act350-pp


Chec

kwei

ghin

g

data combined with high accuracy are key components required in these harsh and sometimes hazardous environments.

Improved PerformanceThe design of the new C-Series check-weighers from METTLER TOLEDO allows for much tighter tolerances at higher line

Automated WeighingManufacturers increasingly see the value of replacing labor-intensive static spot-checks with automated, 100% in-line quality inspection using dynamic checkweighers. This ensures Weights and Measures compliance and minimizes give-away. It also improves production ef-

ficiency, reduces labor needs and releases operator resources to focus on other pro-duction tasks. Checkweighers can play a leading role in cost reduction programs, especially if they have been designed to meet the strict requirements of manufac-turers who operate within the meat and poultry sector. Full visibility of production

4

C31 StandardLineC31 is the reliable choice for daily weighing tasks. The checkweigher ensures high weighing accuracy and flawless product flow, avoid-ing downtime.

C35 AdvancedLineC35 with its exceptional weigh-ing performance is designed for all production environments. It is configurable to ensure a versatile solution in any challenging appli-cations.

C33 PlusLineC33 is the best in class solution. The robust design of the check-weigher supports high weighing performance and throughputs – the perfect solution for daily pro-duction routines.

Performance Improved by 30%Higher Accuracy Under Extreme Conditions

In times of increasing globalization, manufacturers in the meat and poultry sector are facing

challenges in their production processes to reduce costs and increase efficiency. Dynamic

checkweighers play a key role in addressing these demands.

METTLER TOLEDO Processed & Packaged Food News 23 5

speeds. In many cases, production speed can be increased by more than 30% com-pared with existing systems on the mar-ket. Rapid set-up and simplified product changeover also contribute to process ef-ficiency. At the same time, product-han-dling improvements remove out-of-spec-ification products without stopping the line.

Advanced Line IntegrationIntegration is far more than simply hav-ing a solution that will fit into the space available. Connectivity solutions ensure that all production data can be collected. The C-series checkweighers are equipped as standard with an interface for all major industrial data protocols to support In-dustry 4.0 initiatives. Secure operator ac-cess and complete logs of all events sup-

port audit protocols. Feedback to filler software allows proactive fill level control.

Thus the new C-series range does much more than just weigh. In a world where efficiency and profitability must be con-tinually improved, deploying the most versatile and precise solutions gives man-ufacturers the competitive edge they need.

www.mt.com/checkweighing-pp

Choosing the Right Solution

See the full checkweigher product range and find out which solution is best suited to your application. Download our guide:

www.mt.com/c-series-pi-pp


Stop OverfillingTight Process Control Reduces Costs

Stat

istic

al Q

ualit

y Co

ntro

l

When producing millions of products every day, process control is imperative. A German

chocolate bar manufacturer is managing their steadily growth by realizing measurable

productivity improvements and cost reductions with leveraging technology to optimize its

filling process.

products are inspected with automatic checkweighers. Data from all check-weighers are collected and reviewed with FreeWeigh.Net® statistical quality and process control software.

The goal is to optimize filling so un-der-filling is eliminated and overfilling

With over 3 million chocolate bars pro-duced every day, Ritter Sport is one of the largest chocolate brands in Germany. The family-owned company is known for their square chocolate bars that are exported to more than 100 countries. Net content and foreign body control is performed at dif-ferent control points along multiple pro-

duction lines to maintain the high qual-ity standards that make them a favorite worldwide.

Two ways to reduce overfilling The company uses two methods to check net content. Square bars are manu-ally checked whereas specialty bagged

6

Quick Response to DeviationsImmediately react to any devia-tions and minimize downtime. • Receive immediate notifica-

tions via email or SMS wherever you are.

• Benefit from trending function-ality to detect tolerance viola-tions and minimize process interruptions.

A Range of Quality Control DataControl the full spectrum of qual-ity data by collecting attributes or adding results of visual checks to the database.Ensure package quality by testing:• Expiration dates• Label print quality• Moisture data

No Growth Limits Expand quality control set-up at any time with minimal effort.• Easily integrate third party

devices.• Scale up from a compact

single station to a networked system.

• Monitor your results from a PC or from a production terminal touch screen.


minimized. Square chocolate bars are checked immediately after the bars have been pressed out of the molding form. An operator takes samples from the belt at a predefined time interval. These sam-ples are checked on a METTLER TOLEDO ICS bench scale and the data is stored and managed with FreeWeigh.Net®. With a daily production of more than 3 million bars, reducing overfilling by just 1 gram can save the company about 3 tons of raw material every day.

With FreeWeigh.Net®, all results can be monitored at the point of production, as well as from a remote PC or mobile de-vice. In the event of a process deviation, the operator is immediately informed and can follow instructions provided on the screen to make adjustments. This en-ables fast intervention and reduces addi-tional overfilling costs.

Optimized net content controlWhen exporting to so many different countries, adhering to various net content requirements can be a challenge. Free-

Weigh.Net’s integrated tolerance system supports Ritter Sport in complying with national and international net content legislation and global food standards. The control software helps with optimizing fill quantities based on local requirements.

Grow with production needsA wide range of standard devices and spe-cialized instruments can be run with FreeWeigh.Net®. Checkweighers, metal detectors and other instruments can be linked and integrated into a single qual-ity-reporting system.

Ritter Sport has been pleased with the easy integration provided by FreeWeigh.Net, as well as the software’s ability to grow with its production needs. Company management is confident that METTLER TOLEDO products will continue to be an integral part of Ritter Sport’s operations well into the future.

www.mt.com/FreeWeigh-pp

Minimize Overfilling

Watch this video to understand how FreeWeigh.Net can reduce overfilling and provide compliance to net content control. Watch video:

www.mt.com/FreeWeigh-pp


Modular Titration ExcellenceTailored to Your Needs

Titra

tion

The new generation of Titration Excellence builds upon the proven

modular concept broadening the analyses offering with automated

sodium analysis and coulometric Karl Fischer titration. Titration Ex-

cellence speeds up routine analyses by automating data transfer

and making operation more intuitive thanks to the high-resolution

touch screen. Start analyses with just OneClick™ and have confi-

dence in your analytical results.

8

Direct Sodium DeterminationThe standard addition technique for direct sodium determination is an integral part of the new Titra-tion Excellence. Automated direct sodium determination can now be carried out on a whole sam-ple series.

Karl Fischer ModularityPerform coulometric KF titration on all Titration Excellence instru-ments. The new coulometric mod-ule improves Bromine Index de-termination and requires no extra bench space.

www.mt.com/titration-pp

Secure Routine Operation StatusLight™, the interplay of light and sound, supports routine op-eration with visual and acoustic signaling. Stay in touch with your titration from anywhere in the lab!


Gokul, a well-known and popular dairy brand in India, produces a diverse range of typical Indian specialties, such as dahi, lassi, paneer, shrikhand, etc. Gokul’s high quality dairy products are very much ap-preciated by the Indian market.

Sodium determination for safe milkMETTLER TOLEDO met with Mr. S.P. Samudre, QC Manager at the produc-tion site of Kolhapur who emphasized the importance of sodium determination in Gokul dairy products:“Sodium determination is one of the most important parameters in our routine test-ing. By measuring sodium content in milk we can control for adulteration, since certain types of caustics are some-times added to old stocks of milk to lower acidity values. Sodium determination is carried out to identify such adulterants.”Until now, sodium determination for raw

milk was tested qualitatively using a col-orimetric method. Seeking a faster and more satisfactory method, Gokul decided to trial METTLER TOLEDO’s Sodium An-alyzer to test all dairy products for so-dium content plus caustic residues used in the Cleaning-In-Place system (CIP). Mr. S.P. Samudre commented on his positive experience using METTLER TOLEDO’s Sodium Analyzer:“Today we are measuring an average of 40 samples per day using the METTLER TOLEDO Sodium Analyzer. We appreci-ate the easy set-up, reliable results and touch screen, which features an intuitive user interface.”

www.mt.com/sodium-determination-pp

Quick and Reliable Sodium Determinationin Milk and Dairy Products

Consumers frequently study the nutrition labels on prepackaged foods as a means to

control certain foods in their diet, such as salt intake. Gokul, an Indian dairy company,

explains the importance of sodium determination in their products.

METTLER TOLEDO EasyPlus™ Analyzer used for sodium determination in Gokul products in an Indian dairy company.

Learn More about Sodium Determination Techniques

Follow the link below to find detailed information on sodium determination techniques, including an application brochure, standard addition poster, and links to our titration webinars.

Check out our sodium application brochure here: www.mt.com/sodium-determination-pp

Health Risks of Sodium IntakeToo much sodium increases your risks for high blood pressure, and high blood pressure is the leading cause of heart attack and stroke.

Health risk factor in EU#1

80% 58%Results from an Amerian Heart Association survey of 1.000 U.S. adults in November 2013.*

*Mattes and Donnelly, J Am Coll Nutr. 1991; 10:383-393

Exceed the recommended daily upper intake of sodium.

On average American adults eat more than 3400 mgof sodium daily - more than double the American Heart Associaton‘s recommended limit of 1500mg.

1500 mg 3400 mg

Increasing demand for sodium content determination and declaration for Food & Beverage industry

Code of Federal Regulations

Labeling regulations require sodium content claims on food and beverage products.

European Commission Health and Consumer Directorate-General

Nutritional elements with importance to public health, such as saturated fat, sugars or sodium, are mandatory nutrition information.

Regulations aim for respect that final consumer easily understands the information provided on the labeling.

Standard Addition Ion Selective Electrode (ISE) Atomic Absorption Spectrometry Ion Chromatography (IC) Thermometric Titration

Minimal user skills Minimal user skills Advanced user skills Advanced user skills Advanced user skills

Low investment High investment High investment High investment High investment

No external calibration External calibration External calibration External calibration External standarization

Fast preparation & analysis Fast preparation & analysis Long preparation & analysis Long preparation & analysis Fast preparation & analysis

What Technique is Best for Sodium Determination?

www.mt.com/sodium-determination

METTLER TOLEDO Standard Addition stands for:

Efficient and SecureTitration Excellence

Simple and AccurateSodium Analyzer

Processed and restaurant foods

77%

Naturallyoccuring

12%

Addedwhile eating

6%

Addedwhile cooking5%

Processed and restaurant foods

77%

EU-Regulation 1169/2011

USA Federal Regulation, 21 CFR PART 101.61, revised April 2013


X33 x-ray system inspects processed ready meals

Quality Without CompromiseNext Generation X-ray Adds Protection

X-ra

y In

spec

tion

A large US manufacturer of gourmet lasagna ready meals decided to invest in food x-ray

inspection due to the latest developments in x-ray inspection technology, making it a viable

solution for their brand protection.

METTLER TOLEDO, and they said that their systems could handle our products easily. But, given our past experience, we wanted a supplier that could support us with a locally-based technician.”

METTLER TOLEDO was able to provide the necessary support. “The engineer we worked with was knowledgeable. He in-stalled the unit, set it up and trained our team. It’s good to know that if we run into any issues, he can be here quickly to get us back up and running.”

Next-generation solutionsZinetti installed an X33 x-ray inspection system with features a 20-watt x-ray gen-erator that, when compared to the previ-ous 100-watt generator, dramatically re-duces power usage while maintaining high detection sensitivity.

Similar to other X-series models, the X33 provides outstanding detection sensitiv-ity to identify metal, glass, calcified bone,

Zinetti Food Products has an unwaver-ing commitment to producing the high-est quality products. To help ensure food safety, Zinetti installed a METTLER TOLEDO Safeline X33 x-ray inspection system.

“We originally started looking for an x-ray system several years ago,” says Ash Engele, Maintenance Manager at Zinetti Foods. “We even installed a unit from an-other supplier on a trial basis in 2008 but we got a lot of false rejects and decided it wouldn’t work for us. At the time, we

found x-ray inspection was perhaps better suited for products that are more homog-enous than ours.”

Overcoming limitations The limitations Zinetti experienced in x-ray performance have been overcome more recently. Advances in x-ray inspec-tion systems and the software used to sup-port the technology have made huge steps, bringing x-ray into the mainstream of food-industry product inspection. “We decided to revisit x-ray solutions last year,” says Engele. “I spoke with

10


mineral stones and other dense materi-als, enabling the removal of contami-nated products from the line. It can also measure gross mass for portion control, inspect for packaging defects and check package seal integrity.

Quality is key“We rely on outside vendors for ingredi-ents. Contamination possibilities are end-

less and our x-ray system gives us another layer of protection. As we grow, our risk grows along with our volume; X-ray in-spection is another step toward ensuring food safety. It gives us and our retail cus-tomer’s the confidence that we’re main-taining the highest product quality stan-dards” Engele concludes.

www.mt.com/safeline-xray-pp

More than Contaminant Detection

X-ray inspection can be used as a con-taminant detector in any food safety program. It can also be used for:• Mass measurement• Package integrity inspection • Contents checking• Fill-level control

For more in-depth information about the benefits x-ray technology can bring to your production processes, down-load our white paper:

www.mt.com/xray-integrity-pp

Whi

te P

aper

X-ray InspectionMore Than Just Contamination Detection

Contents

1 Why Use X-rays to Inspect Products?

2 How Does X-ray Inspection Work?

3 X-ray Inspection Sees What You Can’t See

3.1 Measurement of Product Length, Width, Area,

and Volume

3.2 Identification of Missing or Broken Items

3.2.1 Detection of Damaged Products

3.2.2 Detection of Missing Products

3.2.3 Insert Inspection

3.3 Measuring Mass and Monitoring Fill Levels

3.4 Product-in-Seal Inspection

4 Conclusion: No Shocks or Surprises

Detecting all contaminantsX-ray technology can be used to detect a broad range of physical contaminants including:• Glass• Metal• Mineral stone• Dense plastics• Calcified bone

www.mt.com/ind-ppFor more information

Calibration and ValidationAre You Compliant withthe Latest ISO Revision?

Recent changes in standards and ISO regulations have again increased the effort required of food manufacturers. Two new webinars help processed and packaged food manufacturers optimize service visits and comply with latest regulations.

Seven Easy Ways Service Reduces the Risks of Non-ComplianceThis new webinar details the seven service elements that make it easier for food manufacturers to comply with the latest food safety standards and regulations.

www.mt.com/pi-service-webinar-pp

Reduce Calibration Costs with Risk-Based AnalysisThis 15-minute webinar details how an ISO certified company can optimize calibration efforts based on the latest ISO 9001 re-vision by mounting a risk-based analysis.

www.mt.com/ind-iso9001-pp

New Industrial Weighing Catalog

www.mt.com/ind-catalog-pp

Free Download

Local contact: www.mt.com/contactsDocument No. 30327501

Mettler-Toledo, LLC1900 Polaris ParkwayColumbus, OH 43240

Mettler-Toledo Hi-Speed5 Barr RoadIthaca, NY 14850

Mettler-Toledo Safeline6005 Benjamin RoadTampa, FL 33634

Mettler-Toledo CI-Vision2640 White Oak Circle, Unit AAurora, IL 60502

Mettler-Toledo, Inc.2915 Argentia Road, Unit 6Mississauga, Ontario L5N 8G6

Documents

Processors Invest in Automation Throughput to Increase by 14%