News. Specialty Chemicals. Manufacturing the secrets of passions and well-being. Industrial Weighing and Measuring

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Everett Kennedy
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Specialty Chemicals Industrial Weighing and Measuring 4 News Manufacturing the secrets of passions and well-being Fragrance oils are complex combinations of natural and synthetic aromas, created by

At Takasago Europe Laboratory, more than 200 liquids, among 2000 different raw materials, are dosed automatically for the manufacturing of hundreds of fragrances.

1 Specialty Chemicals Industrial Weighing and Measuring 4 News Manufacturing the secrets of passions and well-being Fragrance oils are complex combinations of natural and synthetic aromas, created by the finest noses. To keep their unique character, fragrances require accurate and reliable formulation solutions scaling up to industrial production lots. At Takasago Europe Laboratory, more than 200 liquids, among 2000 different raw materials, are dosed automatically for the manufacturing of hundreds of fragrances. These automated systems require instrumentation that captures and processes data at high speed while ensuring high accuracy and reliability. Formulations may contain more than 100 different raw materials, of which some are required to be dosed in amounts as low as 0.05% of the total formula weight. Furthermore these tiny amounts must be weighed within very strict tolerances of 0.5 2%. Such a manufacturing challenge can only be handled by a METTLER TOLEDO high-precision weighing solution. Just in time, flexibility, 1 product for 1 customer, reliability and accuracy are what Takasago offers to their customers, says Mr. Dupont Quality Director of Takasago Europe Perfumery Laboratory in Paris. METTLER TOLEDO helps Takasago to continuously satisfy their markets by implementing tailored solutions and services.

2 High-precision formulation solutions Publisher Mettler-Toledo AG Industrial Heuwinkelstrasse CH-8606 Nänikon Switzerland Production MarCom Industrial CH-8606 Nänikon Switzerland MTSI 44099068

by specific software that is integrated into SAP. This software guides a mobile system with a high-precision scale, connected to a weighing indicator, to the right raw material pipeline.

At the same time, this precise, fast and automated weighing solution, allows Takasago to increase productivity as well as formulation quality.

2 2 High-precision formulation solutions Publisher Mettler-Toledo AG Industrial Heuwinkelstrasse CH-8606 Nänikon Switzerland Production MarCom Industrial CH-8606 Nänikon Switzerland MTSI Tailored solutions for any manufacturing challenge Subject to technical changes 04/2007 Mettler-Toledo AG Printed in Switzerland METTLER TOLEDO Specialty Chemicals News 4 Every formulation is managed by specific software that is integrated into SAP. This software guides a mobile system with a high-precision scale, connected to a weighing indicator, to the right raw material pipeline. Hundreds of compounds are then dosed in the same container automatically. The weighing solution ensures that essences and chemicals are weighed according to the tolerances required. At the same time, this precise, fast and automated weighing solution, allows Takasago to increase productivity as well as formulation quality. Takasago Europe Perfumery Laboratory, located in Paris, is part of Takasago International Corporation, a US$1 billion Japanese company operating in Flavors, Fragrance, Fine & Aroma Chemicals production for over 80 years. Today Takasago is the largest flavor and fragrances company in Japan and one of the leading flavor and fragrances companies in the world. More than 200 liquid raw materials are dosed automatically. Each drum is identified by barcode and managed within the Enterprise Resource Planning system. The SAP software guides a mobile system with a high-precision scale and the weighing indicator to the right raw material pipeline for exact dosing of liquid premixes.

Supreme noise and vibration control Liquid and powder premixes, coming from previous production steps, are added to the mixer where the end fragrance product is manufactured up to a maximum batch

Embedded in the weighing indicators is TraxDSP, superfast, multi-stage digital filtering software that provides maximum accuracy during filling and mixing processes.

capabilities, all components are added accurately to the huge mixer as if there was no agitation or harsh environment.

3 Supreme noise and vibration control Liquid and powder premixes, coming from previous production steps, are added to the mixer where the end fragrance product is manufactured up to a maximum batch size of 22 tons. For this all-in-one mixing step the IND560 process weighing instrument helps Takasago achieve the highest product quality at high speed. Embedded in the weighing indicators is TraxDSP, superfast, multi-stage digital filtering software that provides maximum accuracy during filling and mixing processes. TraxDSP updates weight signals very fast and eliminates noise and vibrations generated for example: by tank s mixing due to the presence of nearby machinery in unstable environments Due to these capabilities, all components are added accurately to the huge mixer as if there was no agitation or harsh environment. IND690 Up to four scales/balances connectable Water and dust-proof Wide variety of software Pacs such as Count, Form, Com, Sum, Fill, Batch, Control, FormXP Broad interface range available: Ethernet, WLAN, USB, Bluetooth, Profibus DP Material identification through barcode reader and RFID IND560 Water and dust-proof Easy to operate filling solution: the Fill-560 application software allows prompt configuration of sequences for filling, blending, dosing and dispensing TraxDSP filtering system provides accurate weight measurements even in unstable environments High reliability: calibration management monitors performance and alerts operators of maintenance needs for maximum uptime Installation, configuration, calibration, maintenance, documentation or, in one word, high quality service: this is why Takasago chooses METTLER TOLEDO says Mr. Dupont Quality Director at Takasago Europe Perfumery Laboratory. METTLER TOLEDO Specialty Chemicals News 4 3

Integrated weighing solutions Formulating babies happiness Staying dry and feeling smooth is a matter of having the right weighing solution in the manufacturing of baby diapers.

In fact the basic nonwoven material is made of polypropylene fibers having natural hydrophobic characteristics.

Thus the absorbent core takes up liquors rapidly, and the diaper surface stays dry and feels smooth.

4 Integrated weighing solutions Formulating babies happiness Staying dry and feeling smooth is a matter of having the right weighing solution in the manufacturing of baby diapers. Accurate chemical dosing and formulation of finishing liquors is a key factor for making nonwoven webs for baby diapers hydrophilic. In fact the basic nonwoven material is made of polypropylene fibers having natural hydrophobic characteristics. Hydrophilic surface finishing for the top layer of baby diapers results in best wetting properties of the nonwoven web. Thus the absorbent core takes up liquors rapidly, and the diaper surface stays dry and feels smooth. Andritz Kusters was commissioned to provide the finishing process for a new production line making nonwoven spunbond material at a production speed of up to 800 m/min. The solution consists of the nexkiss twin, an innovative finishing machinery concept for low add-on. The liquor preparation and formulation equipment is a fundamental part of this sophisticated technical concept. The correct formulation of the chemicals combined with high-performing nonwoven technology guarantees best product results. The components for a number of different recipes are dosed accurately within tolerances of 5 % into 600 liter tanks. From the tanks the liquor is sent to the machine for nonwoven surface finishing. METTLER TOLEDO weigh modules turn the formulation tanks into reliable weighing systems. The net weight, gross weight, and tare value are sent through a signal transmitter to the control unit (PLC), which manages the whole finishing process. The METTLER TOLEDO solution offers a quick and easy installation, it reduces maintenance costs, and it supports high process uptime and high productivity. The perfect teaming up between Andritz Küsters s proficient engineering and the advanced weighing solutions from METTLER TOLEDO ensures certified diapers quality, day by day. Andritz Küsters provides turnkey systems for the treatment of polypropylene nonwovens for the diaper manufacturing industry. High performing weighing solutions from METTLER TOLEDO are embedded within these systems. 4 METTLER TOLEDO Specialty Chemicals News 4

Key benefits Great formulation accuracy Continuous production uptime without unexpected failures Quick and easy installation Reduced

The offer ranges from individual components to turnkey solutions.

Innovative concepts by Andritz Küsters tuned to the highspeed demands of the dynamic nonwoven industry allow for more production flexibility

The IND110 load cell signal transmitter offers an easy and fast way to connect a set of weigh modules to process control equipment.

Kerstin Lohr, project engineering of Andritz Küsters Nonwoven comments: For us the success of our customers is our success.

5 Key benefits Great formulation accuracy Continuous production uptime without unexpected failures Quick and easy installation Reduced maintenance costs Andritz Küsters is one of the world s leading suppliers of machinery for the nonwoven industry. The offer ranges from individual components to turnkey solutions. The enterprise provides products and services in calendering and finishing technologies as well as complete wetlaid nonwoven lines. Innovative concepts by Andritz Küsters tuned to the highspeed demands of the dynamic nonwoven industry allow for more production flexibility and ultimate added value. The IND110 load cell signal transmitter offers an easy and fast way to connect a set of weigh modules to process control equipment. Additionally, the digital filtering provides a stable reading in applications where vibrations are present, thus providing maximum accuracy during filling and mixing processes. Formulations and recipes can be directly selected via an easy-to-use touchscreen and are controlled by the integrated PLC. Kerstin Lohr, project engineering of Andritz Küsters Nonwoven comments: For us the success of our customers is our success. METTLER TOLEDO weighing systems are not only our reliable partner but also partners of our partners. The perfect teaming up guarantees best quality results to our customers. 4-20mA Integrated Process Control FlexMount weigh modules Anti-lift device restrains tank from tipping Carbon steel and stainless steel design Accuracy: 3000d OIML & NTEP d class IIIL FlexMount capacity range: 220 to kg (250 to lb) Hazardous Area: ATEX and FM approvals Zone 1/21 or Division 1 METTLER TOLEDO Specialty Chemicals News 4 5

6 Truck scales solutions Secure material flow with reliable truck scales At Repsol YPF, Tarragona, Spain, more than 200 trucks pass daily over the nine METTLER TOLEDO truck scales to deliver

Repsol YPF is one of ten major private oil companies operating in more than thirty countries and is the market leader in Spain and Argentina.

6 6 Truck scales solutions Secure material flow with reliable truck scales At Repsol YPF, Tarragona, Spain, more than 200 trucks pass daily over the nine METTLER TOLEDO truck scales to deliver chemicals to some of the world s most important consumer goods manufacturers. Repsol YPF is one of ten major private oil companies operating in more than thirty countries and is the market leader in Spain and Argentina. In addition to refining, Repsol YPF produces chemicals, plastics and polymers totaling more than 5 millions tonnes per year. Their Spanish facility in the Tarragona industrial complex produces nearly a million tonnes of petrochemical monomers and derivatives, such as styrene, polypropylene, polyethylene, polystyrene, polyurethanes and glycols. The recent renovation of the propylene oxide/styrene monomer plant consolidates Repsol YPF s presence in the European polyolefin business, making the company even more competitive. ZONE 1/21 DIVISION 1 POWERCELL MTX load cells 25 90t/ lbs Instant failure notification IP68/IP69K protection (NEMA 6P) 3000e 6000e 5000e e NTEP ATEX Zones 1/21 & 2/22 FM Divisions 1 & 2 approved Integral lightning protection Digital monitoring and correction METTLER TOLEDO Specialty Chemicals News 4 To keep up with the growing business, Repsol YPF needed to deliver fast and reliable control of their inbound/outbound vehicle traffic while ensuring 100 % accuracy and compliance with regulations. To accomplish this, Repsol YPF selected weighbridges equipped with powerful POWERCELL MTX brand load cells. 1. At the entry gate, truck drivers identify themselves with a Radio Frequency ID (RFID) badge to a METTLER TOLEDO unattended terminal. If required, the terminal prompts the drivers for further action or additional data, which they can enter on the local keyboard. Once validated the system automatically tares the scale. Then the weight is transferred to Repsol s SAP system via METTLER TOLEDO s vehicle scale management software and a tare receipt is printed for the driver. A traffic light signals to the driver that the transaction is completed and he can proceed to the filling station. Courtesy Repsol

2. At the filling bay, classified as a Zone 1/21 hazardous area, the driver identifies himself again to recall the truck identification, tare, driver data and order information.

METTLER TOLEDO POWERCELL MTX load cells and all equipment installed at Repsol s filling bays meets the ATEX directive for explosive environments.

7 2. At the filling bay, classified as a Zone 1/21 hazardous area, the driver identifies himself again to recall the truck identification, tare, driver data and order information. The fill weight is retrieved and the METTLER TOLEDO scales and local PLC s accurately control the filling of the truck. METTLER TOLEDO POWERCELL MTX load cells and all equipment installed at Repsol s filling bays meets the ATEX directive for explosive environments. Communication to SAP takes place via low power, high speed, fiber optic data transmission. 3. After filling, the vehicle is weighed again on one of the 60 tonne weighbridges before it leaves the plant. This confirms the fill weight and that the vehicle has left the facility in a timely manner. At the end a ticket is printed with all relevant data, such as the material, the truck tare and actual net weight. All data is automatically transferred into the SAP system for further processing. Key Benefits Speed and flexibility to easily adapt to customer demand Minimize product loss through overfilling Eliminate product give-away 100 % inventory management and control Full compliance with hazardous area regulations Complete calibration and maintenance services Security through automatic RFID No data loss because of manual transaction errors Courtesy Repsol The Repsol operator starts the filling process manually. Courtesy Repsol METTLER TOLEDO Specialty Chemicals News 4 7

8 Building quality into your process Great quality is the result of your process know-how, your people s skills and reliable operations. Quality also depends on using the right piece of equipment and on minimizing risks associated with such devices. A weighing system can be a very accurate device and deliver great reliable results, day in and day out. However, each measurement technology is associated with systematic and random potential errors that could affect your process and your product quality. The measurement of a weighing system, for example, can be affected by changes in the environment, it possesses a statistical rounding error, and may display repeatability variations or linearity errors. This is nothing to worry about as long as the sum of these potential errors the measurement uncertainty is quantified and set against your process tolerances. By determining the measurement uncertainty of your scales at regular intervals you get the peace of mind that your equipment always fits your process criteria. You might ask, does calibrating a scale ensure that it is accurate enough? The answer is yes, if the measurement uncertainty is determined by testing the scale at the point of use, ensuring that uncertainty results are smaller than your acceptable process tolerances. At METTLER TOLEDO, we use powerful calibration management systems, such as the proprietary MiraCal, that ensure reliable calibration procedures. During testing, the measurement uncertainty of the weighing system is determined and the resulting minimum weight certified. With our calibration services you receive straightforward benefits: increased safety, minimization of risks, optimization of uptime and the peace of mind of delivering the same great quality to your customers. METTLER TOLEDO calibration services help ensure accurate measurements and thus build quality into your process. Mettler-Toledo AG CH-8606 Greifensee Switzerland Tel Fax Your METTLER TOLEDO contact: For more information

from manual operation to a fully automatic dispensing system with IND690fill. Just plug and play!

from manual operation to a fully automatic dispensing system with IND690fill. Just plug and play! Fine Chemicals Industrial Weighing and Measuring News 5 Speed up your filling processes also in classified areas Manual or semi-automatical, filling of drums or large bags requires great precision. Standalone,