Complete Quality Control System A Solution for Filling for the Food Industry

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1 Bakery, Snacks & Sweets Industrial Weighing and Measuring News 7 Complete Quality Control System A 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 filler operators were not performing the Statistical Quality Control (SQC) process correctly. The customer needed a method by which they could monitor fill weights and attributes such as product appearance, labeling, and expiration date on a real-time basis enabling immediate adjustments to be made to their processes when required. METTLER TOLEDO fills in the gaps After hearing about the customer s problem, METTLER TOLEDO performed a site-study to find out exactly where inefficiencies were occurring. An equipment specification and recommendation was delivered to the customer shortly after the visit. Both METTLER TOLEDO and the customer determined that the project could be delivered in two phases over a 6 month period. During Phase I of the project, the customer installed a single station consisting of one ID30 an industrial PC weighing terminal and a KA15s weighing platform (15 kg 0.1 g) a stainless steel, high-precision scale base capable of withstanding wet wash-down environments. FreeWeigh.Net the METTLER TOLEDO Statistical Quality Control software was installed so the customer could track the filling process. Immediate adjustments FreeWeigh.Net records and tracks net weight and other quality data from samples taken off the production line. From the sample data it calculates production mean, range and standard deviation, which is the basis for quality assessment. For operators and supervisors this data is

2 Statistical Quality Control Attributes and testplans module: Input of product quality attributes from visual inspection and execution of Testplans-linking individual measurements and checks together to a sequence. Ensures completeness of quality data Simple operation Graphical representation Production Line 1 Production Line 1 Production Line 1 Production Line 1 Ethernet Configurable quality docmentation Master station Supervisor s office Graphical representations and analysis of net content and other quality data made available online on the PC-terminals. This data is crucial for immediate adjustment decisions and is made available to operators and supervisors on a PC-terminal at the production line. The result is much tighter control over the process and drastic reduction in overfill. Configurable reports are generated automatically by FreeWeigh.Net being the quality documentation of the produced batches without requiring additional effort by the company s personnel. The system completely paid back The customer noticed an immediate difference in inventory and after six months the Phase I system completely paid for itself by reducing overfill costs. Based on the success of the first phase, the customer completed Phase II of the project by installing additional equipment into their facility. The final system includes four ID30 workstations with KA15s weighing platforms and FreeWeigh.Net software which allows the manager to monitor the filling process from a remote PC. An attributes module was added to the FreeWeigh.Net installation to track other quality characteristics such as product appearance, labeling, and expiration date in addition to net weight. After Phase II the company now has a complete quality control system. The package was secured with a METTLER TOLEDO service agreement which includes regular calibrations and standard maintenance checks to ensure that the equipment continues to deliver great results. 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 Fast facts: KA15s weighing platform Capacity: 15 kg Resolution: 1g Weights & Measures approved Platform size: 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) 2 METTLER TOLEDO Bakery, Snacks & Sweets News 6

3 Bench and Mobile Weighing For Your Routine Applications in Dry Areas The BBA221 is a scale for your routine applications in dry areas, such as your receiving department or warehouse. Over, ok, under indication for checkweighing, portioning and classifying applications Function key Printing/transferring data The terminal with its large display is fast and easy to operate. The scale offers over/ under checkweighing, portioning, classifying and counting functions. It features a RS232 interface to cover your data communication needs. Furthermore, it is powered either by 4-C size batteries or optionally by a rechargeable battery pack, which enables the scale to be used flexibly across the whole premises. Choose from a wide range of accessories: roller track, ball platter, stand or wall fix- Unit switch indication ture for the terminal. The mm and mm size weighbridges can also be mounted on a cart and used as mobile scales. Easy to operate For manual portioning or checkweighing applications the BBA221 features a straightforward and easy to handle threshold definition system. Activate the application by F function key, store the target weight as well as the predefined tolerances and you are ready to go. Automatic taring allows operation without pushing the tare button. After placing the empty container on the weighing platform, the weight is automatically saved as the tare weight (net indicator appears), this allows fast and time-saving operation and also results in less failure. The weight value For higher precision measurements the terminal features a 10 function, which displays the received value with a higher resolution ( 10) for approximative 20 seconds (not Weights & Measures approved). Mobile weighing: IND221 with cart 10 Function for higher resolution Key benefits and facts BBA221 Easy to perform accurate checkweighing, portioning and classifying measurements Weighing range 6 to 300 kg or lb Max. Resolution: d, 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 BBA221 bench scale Functional design allowing easy, intuitive operation Ball platter Roller track Stands: carbon or stainless steel (300, 600, 900mm) METTLER TOLEDO Bakery, Snacks & Sweets News 6 3

4 Sanitary Equipment Design Sanitary Equipment Design For Your Brand s Reputation 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. Both industry and government are working diligently to reduce the incidence of bacteria s such as Listeria in foods and prevent its growth and spread in food processing plants. Equipment is a potential source of pathogen growth so is it the scale! One of the most important factors to consider when buying scales for the use in food processing are design and construction as related to cleanability and the type of material used for construction. Guidelines to evaluate cleanability The American Meat Institute has established an Equipment Design Task Force with the objective to minimize the spread of Listeria in meat processing plants. This Task Force has established sanitary design principles and criteria in consultation with equipment manufacturers, certifying organizations and government officials. The following 10 principles of sanitary design have been developed. 1. Cleanable to a microbiological level: Food equipment must be constructed to ensure effective and efficient cleaning over the life of the equipment. The equipment should be designed as to prevent bacterial ingress, survival, growth and reproduction on both product and non-product contact surfaces of the equipment. 2. Made of compatible materials: Construction materials used for equipment must be completely compatible with the product, environment, cleaning and sanitizing chemicals and the methods of cleaning and sanitation. 3. Accessible for inspection, maintenance, cleaning and sanitation: All parts of the equipment shall be readily accessible for inspection, maintenance, cleaning and sanitation without the use of tools. 4. No product or liquid collection: Equipment should be self-draining to assure that liquid, which can harbor and promote the growth of bacteria, does not accumulate, pool or condense on the equipment. 5. Hollow areas of equipment such as frames and rollers must be eliminated wherever possible or permanently sealed. Bolts, studs, mounting plates, brackets, junction boxes, nameplates, end caps, sleeves and other such items must be continuously welded to the surface not attached via drilled and tapped holes. PBA430 bench scale Hermetically sealed loadcells, IP68 for prolonged submersion and IP69k for high pressure washdown Open, easy-to-clean construction with no hidden holes 6. No niches: Equipment parts should be free of niches such as pits, cracks, corrosion, recesses, open seams, gaps, lap seams, protruding ledges, inside threads, bolt rivets and dead ends. Minimal horizontal surfaces avoiding remaining water (bacteria) Your benefits Reduce biological and chemical contamination risks Fast and thorough cleaning procedures Fulfillment of hygiene regulations Long equipment life due to rugged design 4 METTLER TOLEDO Bakery, Snacks & Sweets News 6

5 7. Sanitary operational performance: During normal operations, the equipment must perform so it does not contribute to unsanitary conditions or the harborage and growth of bacteria. 8. Hygienic design of maintenance enclosures: Maintenance enclosures and human machine interfaces such as push buttons, valve handles, switches and touchscreens, must be designed, to ensure food product, water or product liquid does not penetrate or accumulate in and on the enclosure or interface. Also, physical design of the enclosures should be sloped or pitched to avoid use as storage area. 9. Hygienic compatibility with other plant systems: Equipment design must ensure hygienic compatibility with other equipment and systems, such as electrical, hydraulics, steam, air and water. 10. Validated cleaning and sanitizing protocols: Procedures for cleaning and sanitation must be clearly written, designed and proven effective and efficient. Chemicals recommended for cleaning and sanitation must be compatible with the equipment and the manufacturing environment. Source: AMI Fact Sheet: Sanitary Equipment Design, Amercian Meat Institute, March 2007 Sanitary scales METTLER TOLEDO has seriously taken these guidelines into account. Constructed after the latest hygienic design guidelines of NSF and EHEDG, our scales withstand harshest cleaning procedures such as submersion (IP68) and high pressure cleaning (IP69k). Profit from hygienically designed scales allowing thoroughly and efficient cleaning! BBA4x9 combi scale 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 Full AISI 304 stainless steel constructions, optional AISI 316 load plates 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. No open threads No product can remain Protected against submersion Dustproof and suitable for cleaning with highpressure equipment 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. 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 Simple Weighing Filling/Dosing Batching/Blending Fomulation/Recipe Inventory Management Inbound/Outbound Vehicle Weighing SQC/SPC/Quality Assurance Counting Over/Under Checkweighing In-Line Checkweighing Mobile Weighing Customer Specific METTLER TOLEDO Bakery, Snacks & Sweets News 6 5

6 Vehicle Scales Reliable Vehicle Weighing with MTX Load Cells With more than in service worldwide, POWERCELL MTX load cells have a proven history of accurate and reliable performance in the toughest environments. MTX load cells are designed to operate reliably in all climates, from the tropics to Antarctica (McMurdo Station, Antarctica, shown average temperature -17 C). The MTX load cell uses proven POWERCELL technology that provides the ultimate in weighing for trucks and rail cars. In addition to weighing accurately in all types of climates, it operates reliably over a long service life. The result is a heavy-capacity load cell that delivers the best value for your money by meeting the real-world demands of vehicle weighing. Reliability Every minute that a scale is not able to operate means lost revenue. MTX load cells are designed to keep your scale running by preventing problems and by helping to solve them if they do occur: that protect against costly damage due to lightning strikes and power surges. It is a key part of our four-stage lightning protection system, which also includes double-shielded cables, current-blocking junction boxes, and a single-point grounding kit. The system was tested by an independent laboratory to simulate a amp lightning strike. Self-Diagnostics Each load cell calculates and transmits a weight 15 times per second. If there is a weighing error, the load cell notifies the scale operator instantly, allowing maintenance personnel to pinpoint the problem and get the scale back in service quickly. Exceptional value When selecting a load cell, consider its total cost of ownership. In addition to the initial purchase price, factor in the cost of downtime, maintenance, service, and lost inventory. Any initial savings from buying economy load cells are eaten up by the increased cost of upkeep. By providing the most reliable heavy-capacity weighing in the industry, MTX load cells give you the best value over the life of your scale. Solid Construction The durable stainless steel load cell performs in the toughest environments. It is hermetically sealed to protect the internal electronic components from damage in wet or corrosive conditions. The water-tight enclosure is rated IP68/69k to withstand continuous immersion and power washing. Debris Protection A pliable boot keeps dust and debris from collecting around the load pin. That allows the load pin to move freely, helping to maintain the scale s weighing accuracy 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 Lightning Protection The load cell has built-in transient voltage suppressors POWERCELL MTX Load Cell 6 METTLER TOLEDO Bakery, Snacks & Sweets News 6

7 Kuchenmeister Ensures High Quality Standards with 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 dynamic checkweighers and Safeline metal detection and X-ray inspection systems. Kuchenmeister, a family-owned bakery, has been producing a range of bakery specialities for over 120 years. The company are market leaders in cakes and are one of the largest bakeries in Germany, distributing over 500 products world wide, under their own and retailer brand names. To ensure the high quality of our products we have to work in strict accordance with our recipes, explains Dr. Zurhelle, Head of Quality Assurance. We have high standards regarding the quality and taste of our products. The computer controlled production equipment in combination with the latest machines and state-of-the-art technology ensure optimised product processes and consistent, high quality products. METTLER TOLEDO installed a CombiChecker to ensure the quality of their Milky Way croissants. This machine combines a checkweigher and a metal detector, ensuring products are not only produced to the required weight but are free from metal contamination. 210 products can be weighed per minute at an accuracy of up to 300 mg. Products that do not meet these standards are automatically rejected, in accordance with strict IFS and Weights and Measures quality criteria. Kuchenmeister s foil wrapped cakes are inspected using METTLER TOLEDO Safeline s X-ray machines which detect and reject products with contamination, missing content or those incorrectly sealed. Despite the metallized film A CombiChecker was installed in addition to the checkweigher packaging, the X-ray system can detect a range of contaminants often originating from the farmers field, gathered in with the raw ingredients. Through METTLER TOLEDO service support which offers competent advice, on-site operator training and verification packages, Kuchenmeister can be confident they can rely on METTLER TOLEDO to ensure optimum production processes, high uptime and consistent high quality products. SAFELINE X-ray machine inspecting foil wrapped cakes METTLER TOLEDO Bakery, Snacks & Sweets News 6 7

8 A Wide Range of Solutions to Improve Processes 1. Washdown net content control: IND469rem/KA3s 2. Halogen Moisture Analyzers 3. Floor scale for dusty and humid areas Share our Knowledge Learn from our specialists our knowledge and experience are at your disposal in print or online. Learn more about all of our solutions for the bakery, snacks and sweets industry at our website. You can find information on a wide range of topics to improve your processes, including case studies, application stories, return-on investment calculators, plus all the product information you need to make an informed decision. Brochures/Catalogs: 1. Statistical Quality Control/Statistical Process Control Brochure 2. Food and Beverages Brochure 3. Industrial Weighing Catalog USA Mettler-Toledo, Inc Polaris Parkway Columbus, OH, Tel. (1) Canada Mettler-Toledo, Inc Argentia Road, Unit 6 Mississauga, Ontario, L5N 8G6 Tel. (1) Mettler-Toledo AG Sales International CH-8606 Greifensee Switzerland Tel Your METTLER TOLEDO contact: For more information