Specialty Chemicals For a better living News

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Specialty ChemicalsNewsFor a better living

Chemistry, the fabric of life

Up to 100% uptime

Full safety in hazardous areas

Highest accuracy & reliability

Complete chemical resistance

Nowadays, the invention, development and production of specialty chemicals is a high-tech science that shapes the here and now in many, often astonishing ways. For achieving your business excellence, your

ideas, innovations, and ambitions are driven by high quality, productivity and safety – values that your suppliers need to understand when wanting to add value to your process.

At METTLER TOLEDO we create com-plete weighing and measuring solutions that enhance your high standards even more. What are your benefits?

From the first soap production in Mesopotamia more than 5,000 years ago to the sophisticated creation of complex fragrances, dyes, or high-performance polymer molecules today, chemicals are making our life easier, safer, more comfortable and pleasurable.

We deliver you the right weighing equipment according to your User Requirement Specification (URS) and make sure it stays that way with our service excellence.

Let us help you make your chemicals special – and our life easier, safer, more comfortable and pleasurable.

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METTLER TOLEDO2

How a flavors & fragrances manufacturer «makes the world smell better1»™

Imagine a group of dedicated indi-viduals charged with the mission to „make the world smell better1“™. And this is why a well-known flavors & fragrances manu-facturer made the slogan his credo.

Our customer has over 180 years of experience and a global team of 70 per-fumers creating the world‘s most memo-rable fragrances. To make their products become an art, they rely on proven, reliable and accurate processes and equipment; equipment, that ensures the flavors & fragrances have the right smell, the right taste and generate the right emotions.

Hot spot “Weighing”. Exactly here’s the place where weighing counts. It’s not just like weighing a bag of potatoes – it’s where the

exact amount of each ingredient is crucial, where differences in milligrams account for tremendous variations in smell. Should it be green and fresh like lilies or cool like lavender? It’s all about weighing the right ingredients in exact quantities. But, what are we talking about? Illusive chat or hard facts?

Let us outline it: Our customer in Japan has one factory in Honshu Island where flavors are produced. A savoury team combines the art and science

of flavor making to deliver highly innovative, success-ful products. They have been using METTLER TOLEDO equipment for more than 11 years now.

Memorably, our customer is the only fragrance company with its own perfumery school where many of the world‘s leading perfumers have been trained. Perfumers from this school have created 1 out of every 3 fragrances that exist in the world today.

METTLER TOLEDO helps to «make the world smell better1»™

“For nearly two centuries, we‘ve been studying taste preferences all over the world. We know that flavor creation depends on understanding people and the times they live in. It is, in most ways, not just busi-ness, it’s an art.“

Contents

How a flavors & fragrances manufacturer «makes the world smell better»™

ATEX137 countdown – are you ready?

Made for very bad weather, too

Surrounded by functional polymers – METTLER TOLEDO ensures its quality

Smart IND130 – Direct to destination without detour

Boost your ROI with an effective & efficient Statistical Quality Control System

The best in Weighing & Process Control – METTLER TOLEDO and Siemens partnership

ServiceXXL - Tailored Solutions

Inprint

Publisher

Mettler-Toledo GmbH Industrial Sonnenbergstrasse 72 CH-8603 Schwerzenbach Switzerland

Production & Illustrations:

MarCom Industrial CH-8603 Schwerzenbach Switzerland

Subject to technical changes. © Mettler-Toledo GmbH 04/05 Printed in Switzerland

MTSI44099538

How does a warm summer night smell? Why does a perfume match my mood perfectly? Why does the shower gel I‘m using give me such a rinvigorating and fresh feeling? How does this natural and juicy lemon taste get into my preferred chewing gum?

1 „makes the world smell better“ is a Givaudan trade mark

www.mt.com/specialty-chemicals

Specialty Chemicals News 3

In order to accomplish the high quality benchmark, and to combine all necessary ingredients for a tasty, flavory-rich product for drinks, yoghurts, cookies, etc. they use a manual filling system in each of the 8 filling stations with a support-ive computer system for data collection. The filling stations consist of METTLER TOLEDO ID7sx indicators for hazardous areas and high resolution digital floor scales KES1500x featuring a capacity of

1500kg and an accuracy of 20g – high accuracy counts here also on heavier loads. In addition, bench scales KB60sx are installed featuring a capacity of 60kg and an accuracy of 1g for filling capaci-ties. To complement reliability on smaller amounts Viper Ex compact scales are present too, with an accuracy of 0.02g.

As a true positive testimonial, our customer has replaced all other scales with METTLER TOLEDO weighing equipment.

Customer key benefits• Exact formulation due to reliable,

repeatable and accurate weighing equipment

• Suitability for hazardous areas

• Three platforms connected to one weighing indicator

• Withstands harsh conditions• Easy to clean design• All-in-one solution

ID7sx – Intelligence and precision• Up to Zone 1/21 and Div 1 approved

• Big Weight® Display with graphics capability

• Expandable through software application Pacs such as for Data Processing, Filling and Formulation

• IP65/66 protection

• Serial Interfaces

• 8 digital I/Os available

• Alibi Memory

• Up to 3 scales connectable: Analog and Hi-Res digital

Hi-Res digital floor scale KES1500x• Rugged stainless steel design

• Weighing capacity 1500 kg

• Readability up to 75000d

• Certified resolution up to 32000e

• Excellent repeatability, linearity and corner load stability

• IP66/67 protection

• Hygienic design – easy to clean

Viper Ex – compact weighing• Up to Zone 1/21 and Div 1 approved

• Up to 60kg weighing capacity

• Readability up to 350000d

• Certified resolution up to 35000e

METTLER TOLEDO4

Totalhazardous areasafetyEx+ =

You are ready

You are ready

You are ready

Where are you in this transition phase ?

All your equipmentis ATEX 95 certified

You still have some non-ATEX 95certified equipment running

Your explosion protection document requires you toperforma arisk assessment of such older equipment

You perform a thorough risk assessment andanalyze potential ignition sources of your olderequipment. That includes electrical as well as

non-electrical (mechanical) parts.

You assume responsibility of the older equipment

You replace with ATEX 95 certified equipment You replace such equipment withATEX 95 certified equipment and

transfer the responsability to METTLER TOLEDO

Over the past 30 years, the need to improve conditions in working places has been one of the European Commis-

sion’s primary objectives. One of these – ATEX 137 (EC 99/92/EC) – is currently in transition phase, becoming fully effective

from July 01 2006 (Germany from January 01 2006).

ATEX 137 countdown – are you ready?

Total safety in hazardous areas with METTLER TOLEDO

Simple, flexible, durable: ID3sTx • Easy to install and operate• Flexible power solutions• Low power consumption for a long

battery life up to 380h • Rugged stainless steel construction, IP65• Immunity to electrical interferences

due to fiber optic data communication• Certified for Zone 1 and 21

Friction matters – go with our bench/floor scalesScale frame and mechanical parts are subject to ATEX risk assessment:• Selection of apropriate materials,

which can not initiate an explosion• Design by itself does prevent ignition

sources (for example moving a/o rota-ting parts, that could generate friction or sparks)

• No dead spots for liquids/solids accumulation

• No electrostatic charge build-up• Scale load cells are subject to ATEX 95

electrical compliance

METTLER TOLEDO offers the widest portfolio of weighing solutions certified for explosive environments – from indicators, bench, floor and portable scales to weigh modules up to heavy duty vehicle scales to fit ATEX 95 regulations.

Of the 120 million workers within the EU, every year 10 million are the victim of the work-related accidents or disease and 8‘000 die. (Source: www.siraservices.com)


Mud, snow, water and lightning rou-tinely cause damage to typical vehicle scale load cells (sensors). Many scale users discovered that a damaged sensor doesn’t just cause the scale to fail but to register incorrect weight. The error was only dis-covered during an annual calibration or after a dissatisfied customer complained that they had being cheated – this is usually the result of the reduction of weight caused by a “missing” or non-functioning sensor…bad weather…

METTLER TOLEDO conquered weather, failed sensors and virtually eliminated emergency service calls with the intro-duction of the POWERCELL® brand load cell.

METTLER TOLEDO is continuing our industry first 5-year warranty against lightning strikes and weather related problems with the third generation MTX POWERCELL®. The MTX POWERCELL® has been tested and proven for prolonged submersion, lightning resistance and now is the first digital vehicle scale cell to be tested and proven for IP69K (60°C water jets).

The POWERCELL® is successfully operating in many of the world’s deserts, Siberia and is installed in the only weighbridge in Antarctica.

The only time a scale user sees the service department is during routine main-tenance – this translates into “real cost savings”. In the rare event of a cell failure, usually physical damage to the cell, the POWERCELL® network reports the failure within 300 milliseconds.

Imagine knowing that your scale is delivering dishonest weight in less than one second: No time for dissatisfied customers!

Snow & Cold Lightning

Mud & Ice Water & Flood

Desert & Heat Peace of Mind

Made for very bad weather, too

MTX POWERCELL®

Fast Facts: MTX digital load cells• 5 year warranty

• Over 500000 Installed worldwide

• 25-90t / 55000-200000lbs

• Instant failure notification

• IP68/IP69K

• 3000e - 6’000e OIML

• 5000e – 10000e NTEP

• ATEX zone 1/21 & 2/22

• FM Divisions 1 & 2

• Integral lightning protection

• Digital monitoring and correction

• Temperature changes

• Zero change

• Hysteresis

• Weighbridge creep

Fast Facts: Weigh Bridges• 24/7 use of the weighbridge

• Rugged and long life design

• Low profile

• Corrosion resistant

• All foundation types:

– Pit

– Portable

– Surface mount

• Normal & extreme duty loading

• On road & off road vehicles designs


METTLER TOLEDO6

Predictive maintenance triggers healthier profitsAs capital available for investment shrivels, manufacturing managers need to squeeze the last useful drop of

economic life from equipment. Profitable return on assets is possible through a savvy, up-to-date maintenance

outlook.

Today‘s maintenance practiceReactive = Fixing or replacing equip-ment after it failsPreventative = Assuming a certain level of performance degradation over time and servicing equipment on a routine schedule

The next improvement in maintenance technology is predictive maintenance, which is based on the determination of an equipment‘s condition while in operation. In this way, much more accurate planning is possible, and rapidly progressing faults are prevented from causing catastrophic failures.

100% uptime with the powerful TraxEMT™ predictive maintenance

TraxEMT™ predictive maintenance from METTLER TOLEDO allows you to run your process and plant efficiently and perform maintenance when you want, not when a chaotic failure forces you. It allows you to program the process param-eters that save you from reactive repairs of your equipment. TraxEMT™ provides real-time monitoring of every weighing system sensor. If a sensor is starting to fail, the system immediately informs the responsible personnel.

Key features• Predicts failures before they occur • Alerts individuals of potential failures or

maintenance needs (e.g. by e-mail or on the indicator)

• Performs run-flat estimation in case a load cell would fail. You continue to measure until load cell can be replaced

• Schedules and tracks maintenance• Prevents poor quality and loss of money

caused by product error• Uptime of production and reduction

almost to zero maintenance

“If maintenance in predictive manner equals, for example, $1000, then preventive costs equals $5000 and reactive maintenance equals $15000. But, if you actually end up with an unplanned shutdown, then you’d be looking at >$40000 for costs.”

Stuart Harris, Emerson Process Manage-ment vice president

“You can save 90% on costs on critical assets that have a downtime component.”

Houghton Leroy, ARC Advisory Group analyst

„One savings comes in avoiding un-necessary preventative maintenance. Some of the statistics that I’ve seen are that 40% - 50% of the time, when maintenance is performed, there was nothing wrong with the asset.”

Will Chin, ARC Advisory Group analyst



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Surrounded by functional polymers – METTLER TOLEDO ensures its quality

Functional polymers make stamps self-adhesive and ensure that labels can be peeled off easily. They’re the reason why babies’ diapers stay dry and why ladies’ hygiene articles are getting thinner and more comfortable. With them, paint and plaster can withstand the effects of weather and the environment. Ground frost won’t cause cracks in road surfaces and outdoor tiles will stick to walls even in sub-zero temperatures.

Our customer in Thailand is one of the largest manufacturer of superabsorbent polymers in the asiatic region with an annual production capacity of 20’000 tons. Superabsorbent polymers are the key ingredient in disposable diapers, feminine hygiene and adult incontinence products.

To keep pace with the high-demanding market, our customer runs its batching system 24/7 with highly restrictive quality procedures to avoid production errors that would cause downtime, negative impact on the product quality and probable loss of batch.

The company’s aim is to drastically improve productivity, i.e. almost-zero downtime. This is achieved when the production site shifts from reactive to predictive maintenance.

The Process. During the polymeri-zation process an additive, consisting of exact amounts of initiator and water, is added to the polymerization reaction. This additive suspension is produced in four parallel mixing reactors. The batching cycle of the suspension runs automatically through six consecutive steps:1 If the level sensor in the storage tank

indicates a shortage of the additive solution, a PLC command initiates the production of a new batch

2 Water is weighed-in manually to the mixing tank

3 Initiator (solid) is weighed-in to the mixing tank

4 A high level sensor installed in the mixing tank controls overfilling

5 Under high temperature the two com-ponents are mixed (agitator)

6 The finished batch is discharged to the storage tank

The weighing indicator (JagXtreme) acts as a slave sending weight data over the Allen Bradley RIO interface to the Rockwell ControlLogix PLC

Superabsorbent polymers are materials with the ability to absorb and retain large volumes of water and aqueous solutions.

Storage Tank Mixing Tank

High level sensor

Flexmount Weigh Module

RAAD Box JagXtreme Indicator

Allen Bradley RIO

Low level sensor

METTLER TOLEDO8

Key customer benefits• Highest polymer quality due to

accurate premixing processes• Continuous uptime through predictive

maintenance, fault recognition and recovery

• In-time automated production of additive• Reliable process data integration• Peace of mind through excellence

in process control

The primary customer request was to design a weighing system that was very reliable and accurate, because the additive suspension is a very important element controlling the polymerization’s outcome.

To satisfy the customer requests, METTLER TOLEDO offered a weighing system for all four mixing systems consisting of:• 4 JagXtreme process weighing indicators

with an Allen Bradley RIO interface

• 4 RAAD smart digital junction boxes featuring predictive maintenance

• 4x Flexmount weigh module sets with a capacity of 300kg and an accuracy of 100g

METTLER TOLEDO Solution

Flexmount Weigh Modules• Hazardous area approvals for Zone

1/21 & 2/22 and Div.1 & 2

• Stainless steel load cells

• Anti-tip device restrains tank from tipping

• Accuracy OIML: 3000d

• Accuracy NTEP: 3000d, 5000d, 6000d and 10000d

• Capacity range up to 20t

High performance maintenance with TraxEMT™ turns strain gauge load cells into intelligent sensors:

• Monitors the condition of each indi-vidual load cell and predicts failures before they occur: Alerts designated individuals of potential failures or maintenance needs by eMail/SMS, so that a defective load cell can be replaced, guarding you against costly downtime or product waste

• On load cell failure, «Run Flat» tech-nology allows to continue production runs until the load cell can be replaced

“The RAAD Box system helped us to reduce downtime and gave us peace of mind due the the reliabilty of its predictive maintenance functionality.“Customer plant engineer


Load Cells, Scale bases

RAAD-Box JagXtreme Indicator

Total maintenance• Schedules and tracks maintenance

• Notifies maintenance checks via e-Mail and allows access over LAN/WAN/Internet for global communication

Total connectivity• Analog and serial interfaces

• Profibus® DP, Allen-Bradley RIO, ModBus+, ControlNet, EthernetIP, Ethernet TCP/IP

Wide variety of connectable scales• Up to: 4 analog scales or 4 vessels

on weigh modules, 4 DigiTOL scales, 2 high precision scales

Total flexibility• JagBASIC programming language

• Up to 12 discrete I/Os and 5 freely definable setpoints

JagXtreme & RAAD Box –

the first weighing solution that employs predictive failure analysis


Smart IND130 – Direct to destination without detour

Connect your analog load cells over:• Profibus® DP• Allen-Bradley RIO• RS232

...directly to your PLC or DCS for batch-ing, filling, tank/hopper weighing, and for inventory control without detouring data-flow through any intermediate device such as an indicator, local display, repeater, etc.

Our smart weight transmitter is your painreliever. The IND130 can be placed on the weighing spot close to your tank, silo, reactor or wherever you want to weigh. A stainless steel enclosure guarantees for smooth operation even in harsh environ-ments. Are there any side effects? No, only positive ones.

Key features• Almost-Zero interference due to short

wiring between load cell system and IND130

• Very high data accuracy due to robust fieldbus data transmission

• Reduced installation/maintenance costs• Quick setup-and-running via PC tool• Easy calibration with CalFREE™

without test weights• Stable weight data through TraxDSP™

digital vibration filtering

IND130 quick facts• 4 x 350 Ω load cells

• Stainless steel enclosure (optional)

• Configuration and calibration via PC-tool

• CalFREE™ calibration w/o test weights

• TraxDSP™ digital vibration filtering

• 1 input, 2 outputs and 1 programmable setpoint

• 24VDC power supply (optional)

• DIN-rail mount

CalFREE™ – the easy way to a quick calibration• No need of test weights

• Ideal for higher capacity thanks

• Big savings due to the minute scale calibration

– Enter units, scale capacity and Increment, mV/V gain

– Enter load cell capacity, output and

– Hit enter and you‘re done!

TraxDSP™ – supreme noise and vibration filtering• No loss of accuracy in a dynamic environment

• Keeps pace with your process speed, update rate > 300Hz

• Ideal for mixing, agitating or dynamic processes

• Filters-out background noise and vibration

• Multi-stage digital filter:

– Low-pass filter (0.0-9.99Hz)

– Cutoff corner frequency (0.1-99.9Hz)

– Notch and stability filter


IND130

PLC

PC, DCS

METTLER TOLEDO10

Boost your ROI with an effective & efficient Statistical Quality Control System

Don‘t overfill, save costs!METTLER TOLEDO provides a comprehensive range of

quality control products to meet your predefined product quality requirements,in order to easily find quality problems and to sort them out systematically.

Our SQC products range from embedded compact solutions up to our expert system FreeWeigh.Net with distributed test sites and centralized database.

Statistical Quality Control SQC = The application of statistical techniques to control product characteristics, in order to ensure they meet product specifications.

You could be overfilling your products. FreeWeigh.Net pays off almost instantaneously – a customer success story

Your costs generated permanently for preparing line control charts (Includes sampling process and data collection labor)

Manual reporting FreeWeigh.Net reporting

Total number of charts per month – 640 640

Average time to record data per chart h 8 5

Average time for chart calculations h 0.5833 0 (automatic)

Average hourly costs for line operator USD 75.00 75

Total time preparing charts h 5‘493.33 3‘200

Monthly costs to prepare charts USD 412‘000.00 240‘000.00

Your savings generated through the implementation of FreeWeigh.Net

Monthly savings USD 172‘000.00

Your Return on Investment

Initial Investment• 33 x ID30 Weighing PC• FreeWeigh.Net software network• Uplink modules• Bench scales

USD 550‘000.00

ROI Months 3.19

ID30 industrial weighing PC• Stainless steel housing

• IP69K protection

• Serial, parallel, USB and Ethernet

• Up to 3 analog and digital scales

• Up to 64 I/Os

• TFT flat screen

• Windows® operating system

Customer key benefits• Big savings in production cost through

almost-zero overfilling & waste, and automated report generation

• Compliant for data management and filling, ready for 21 CFR Part 11

• Easy SAP link-up through SAP module



PLC

The best in Weighing & Process Control – METTLER TOLEDO and Siemens partnership

You can benefit from the alliance of two industry leaders. METTLER TOLEDO and Siemens Automation & Drives col-laborate in the weighing systems business. METTLER TOLEDO products are jointly certified to work with SIWAREX weighing controllers.

METTLER TOLEDO manufactured analog weighing platforms and com-pact scales can be directly connected the Siemens PLCs via SIWAREX. METTLER TOLEDO offers weighing capacities from 3kg up to several tons in both general pur-pose and stainless steel, for wet areas as well with IP68 and IP69k protection.

Both parties have a worldwide service network which advises customers on the installation, commissioning and operation of weighing solutions.

Customer key benefits• Time saving access to a globally well

distributed service network• Complete solution offering• Fast & accurate connectivity• No time wasting interlocutions with

two parties – kill two birds with one stone

• Certified plug-and-play solutions

METTLER TOLEDO offers a worldwide integrated service concept, from maintenance and support, to calibration up to validation support. Our Service XXL solutions provide cost effective services to ensure optmized equip-ment uptime, traceability of results, and regulatory compliance.

ServiceXXL Solution Customer Value• Expert validation support• Manufacturer developed Validation Protocols• Software Update & Maintenance Agreements

• Validated Methods ensure 21 CFRPart 11 Conformity

• Monitored user management• Safe data mangement

• Industry specific Equipment Qualification Packages

• Equipment re-qualification• Factory trained and authorized

technicians

• Conformity with industry specific standards• Avoidance of FDA warning letters and fines• Limited start up costs

• Calibration Report ISO 17025• Calibration Certificate ISO 9000• Certification of measurement uncertainty

and MinWeigh

• Accuracy, reliability and traceability of measuring results

• Known measurement uncertainty• Calculated minimum weight and

activated MinWeigh warning function

• Service Agreements• Installation & Repair• Customer Training & Seminars• Application & Technical Support• Service Center

• Control of unexpected expenses• Optimized up-time & productivity• Documented proof of user training• Avoidance of contamination• Service access from remote areas


Validation

Qualification

Calibration

Maintenance & Support

Mettler-Toledo GmbH. CH-8606 Greifensee, Switzerland Tel. +41-44-944 22 11 Fax +41-44-944 30 60

Process Analytics. We’re a leading supplier of analytical measurement solu-tions for the control of liquid production processes. The business unit INGOLD specializes in the parameters pH, DO, conductivity, turbidity and CO2, provid-ing high quality products including sensors, housings, transmitters, cleaning systems, and services. THORNTON, on the other hand, offers measuring solutions for conductivity/resistivity, TOC and other parameters, focusing on applications in power plants and in the semiconductor industry, as well as in ultrapure water processes of the pharmaceutical industry.

Lab Equipment. Pace setting inventions such as the first electronic analytical balance, the fully automatic adjustment feature proFACT, the revolutionary level control, the world‘s first balance with touch-screen user interface and software for quality management requirements and internet communication all have but one objective: to provide you with amazing solutions for your workplace that constantly improve your work processes. For weighings to the nearest 0.0000001g and a resolution up to 50 Million points, you can be sure of one thing: you will find a METTLER TOLEDO product that optimally fits your needs

Checkweighing. GARVENS is one of the world‘s leading manufacturers of dynamic checkweighers. Checkweighers are fast and precise automatic weighers integrated in your production lines that are used for quality control and for monitoring & controlling filling processes. GARVENS checkweighers can achieve a throughput of up to 400 weighings per minute, with high accuracy and without product flow interruption.

www.mtpro.com

www.garvens.com

www.mt.com/lab

Literature

Predictive MaintenanceKeep your process up and running – all the time

Hazardous Area Focus Where Safety comes first

Weighing in the Chemical & Pharmaceutical IndustrySynthesize your vision – we help you measure it


Documents

Specialty Chemicals For a better living News