Field Proven and Patented.
The Strategy
To stay competitive, manufacturing companies must:
• Increase speed of production
• Improve levels of quality
• Lower costs
The Targets
Key Manufacturing Areas:Production & Packaging
Key Process Phases:Material Transfers
Key Processes:Batching & Filling
The Goal
Transfer the exact amount of material, in the minimum
amount of time every
time !
The Current Status
Transfer the exact amount of material by lengthening the material transfer time every time.
Transfer the approximate amount of material in the minimum amount of time every time.
Case 1.
Case 2.
Or the Trade Off ...
The METTLER TOLEDO Q.i Strategy
• Take control of the material transfer phase
• Adapt to account for natural process variability
• Significantly impact:
- overall manufacturing efficiency
- manufacturing costs
- an enterprise's competitiveness.
The Application Markets and Manufacturing Areas
Manufacturing Areas
• Batching
• Blending
• FillingRaw Materials
• Granules
• Powders
• Liquids
• Slurries
Primary Markets • Food
• Beverage
• Chemical
• Specialty Chemical
• Pharmaceuticals
• Other
Video Overview
The Q.i Components
Software and Services
PAC Predictive Adaptive Control
Technology
A Manufacturing Company's Existing or
Proposed Process
Q.iMPACT Matrollers (Material Transfer
Controllers)
Q.iMPACT Matroller Overview
• Embedded with PAC technology
• Easily integrates with leading control systems
• Can be configured on a network to control a few or few hundred scales AND flow meters
Predictive Adaptive Control Technology Overview
• Builds real-time mathematical model of material transfer process
• Predicts exact moment of cutoff in current transfer
• Automatically compensates for process variations
Q.i365 Overview
• Production management tools
• Predictive/preventive diagnostics
• Internet-enabled software to monitor performance
• A team of METTLER TOLEDO experts available around the clock and around the globe to solve problems when needed.
How Q.i Integrates Into New or Existing Processes
Sample
The Benefits of the Q.i Strategy
Increases competitiveness. Grows profits.
Increases speed. Enhances use of investment capital.
Maximizes control. Improves quality.
Decreases waste. Reduces costs.
Measures performance. Drives improvement.
Increases Competitiveness. Grows Profits.
CASE STUDIES TRADITIONAL 2-SPEED
FEED
Q.i
1-SPEED FEED
SAVINGSIMPACT
(US$)
Case Study 1.•Increased Manufacturing Thoughput•Capital Spending Deferment
~120 mins/batch
~72.5 mins/batch
~$ 5 millionin 1 facility.
Case Study 2.•Improved Control•Reduction in Raw Material Usage
$ 4.91 overfeed per batch
$ 0.67 overfeed per batch
~$ 500,000per annumacross 11
batch systems
Case Study 3.•Reduction in Valves, Pipes & Controllers•Reduction in Maintenance Cost
2 Valves
2 Services
1 Valve
1 Service
~$ 90,000 less h/ware +$10,000 p/asaved over 9 material
paths
*These case studies illustrate actual results achieved by consumer goods manufacturers
Increases Speed. Enhances Use of Investment Capital.
Increases manufacturing throughput of batches by up to 30%.
Reduces cost by up to $10,000 per material delivery line.
Traditional Multi-speed
Material Transfer System
Single-speed, On-Off Material Transfer System
BRUTE FORCE Q.i
Maximizes Control. Improves Quality.
Repeatable Control* with
Previous System
Repeatable
Control* with Q.i
% Improvement
Recipe X Molasses 2.2 0.3 86.36
Recipe Y Water 0.11 0.067 62.77
Recipe Y Sugar 0.18 0.04 63.63
Recipe Y Flavor 1.44 0.04 97.22
Results from actual application by consumer goods manufacturer
*+/- % of full scale deflection
Decreases Waste. Reduces Costs.
Improved control tightens tolerances to a previously unattainable level.
Setpoints can be trimmed of the amount material required, reducing previous buffers.
0
10
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40
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Weight in Kgs
# o
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eria
l tra
nsfe
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0
10
20
30
40
50
60
Weight in Kgs
# o
f mat
eria
l tra
nsfe
rs
IDEAL SETPOINT
BUFFER SETPOINT
+ - TOLERANCES
Typical Control Method
Q.i (PAC) Control Method
Figure 1
Figure 2
Less Material Used = Less Waste = Reduced Costs
Measures Performance. Drives Improvement.
Measure performance and analyze
results
Learn, benchmark, improve, and sustain
peak performance
Around the clock and
around the globe
Global Q.i Team Headquarters (U.S)1-614-438-4390(For local contact numbers, visit www.mt.com)