Automated advanced warnings

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1 Processed & Packaged Food Industrial Weighing & Product Inspection 24 News Productivity in Packaged Foods Technology Enhances Automation The need to improve process efficiency in highly competitive packaged food markets is constant. Interconnectivity and direct communication using weighing and inspection equipment with built-in diagnostics delivers real benefits for manufacturers while keeping pace with Industry 4.0 developments. The terms Industry 4.0 and the Internet of Things (IoT) are becoming commonplace as more facilities become smart factories. These terms are at the core of increased automation and process improvement for the processed and packaged food industry. Increasing pressure Manufacturers are finding themselves under increasing pressure to react quickly to fulfill customer requirements. This leads to the need to improve production efficiency and heightens expectations of weighing and inspection technology to deliver solutions that streamline processes, increase automation and provide visibility through realtime data. Automated advanced warnings In traditional manual operations, data is frequently captured, documented and distributed with varying degrees of human intervention. For example, maintenance teams may monitor key parameters of pieces of equipment and log performance manually. But that doesn t necessarily avoid a complete line stoppage that may occur in the event of an unmonitored trend that is allowed to drift outside of acceptable tolerances. Built-in diagnostics can avoid such events, providing advanced warning of potential line stoppage before it actually occurs. This is just one example of how integrated diagnostics can improve day-to-day processes and contribute to improvements in Overall Equipment Efficiency (OEE). Automation

2 Productivity and Automation 1 Truck and 1 2 rail scales 2 Bench and floor scales 3 Automation is the key Modern weighing and inspection equipment monitors performance, collects critical packaging line data, provides live analysis and enables decision-making for increased automation, improved efficiency and higher productivity. Integrated diagnostics for early trend control Many weighing and inspection devices are able to provide automated and realtime control from within the equipment. For instance, a metal detector is able to continuously monitor critical parameters, which allows for less frequent testing. If adverse trends are detected at any point, the system can provide an early warning, enabling adjustment to take place to rectify the issue before productivity is impacted via a system failure. Predictive maintenance with intelligent load cells Additionally, state-of-the-art weighing technology for automation is based on intelligent load cells with integrated microprocessors for signal processing directly at the actual working point. This eliminates data transmission errors and improves measurement result accuracy and consistency. The intelligence in the load cell also allows continuous analysis of the weighing process. This means a failure or even gradual loss of performance can be identified and reported. In contrast, load cells with analog value transmission provide, at best, a general fault message, with no reliable way to diagnose a gradual performance decline of a load cell. Automated fill control Dynamic checkweighers can add further diagnostic capabilities by monitoring the weight of each package and initiating the automatic adjustment of filling systems to optimize target weights and reduce product giveaway. External software support Industry 4.0 can also be supported through the use of external proprietary software packages. Such advanced software solutions are now able to streamline and automate processes. For example, our ProdX software removes the need for mundane manual data-collection processes through the automated harvesting of data from product inspection devices. Additionally, our Collect+ software brings a new perspective to manual processes by 2

3 Cloud-based diagnostics Tanks on 3 4 weigh modules Process sensors 5 Metal detectors 6 Check weighers 7 Vision inspection and serialization displaying key performance indicators from manual portioning and various checkweighing activities. Continuous improvement The ability to collect such detailed information, along with advanced built-in diagnostics software, enables a new and improved approach to process control and optimization a prerequisite for the Industry 4.0 age. Intelligent sensors pave the way for reduced downtime, faster troubleshooting and less waste product, leading to overall improvements in quality, automation and productivity. `` Intelligent process sensors for Industry 4.0 and IoT The current industrial revolution demands smarter machines. We offer sensors for the food packaging industry including weight, ph, CO 2 and O 2. Download Sensors for Process Automation to learn how we can help you design highly competitive and intelligent process equipment. `` 3

4 Recipe Weighing Stop Wasting Time and Ingredients Bring Certainty to Formulation Manual batch preparation must be fast and precise, as small deviations from predefined weighing tolerances can negatively influence consistency and taste. A new formulation scale makes the recipe weighing process easy, traceable, and efficient. The ICS689 has been enhanced with a new formulation functionality, making the terminal an efficient tool for manual dispensing applications. Software clearly guides the operator through a recipe and allows easy and traceable recipe weighing without costly networking infrastructure. Clear operator guidance The terminal can store 50 unique recipes, each with up to 50 different ingredients. By pressing just one button, the operator opens the recipe data library, selects the recipe, and starts the formulation process. The system guides the operator through the process by advising which ingredient to weigh next. Typically, the system is configured to accept the proposed ingredient by confirming and pressing a soft key on the terminal. Once the recipe has been completed, the operator confirms the end of the process and the batch data is stored in the terminal memory database. Soft keys for user guidance The scale offers different visuals and soft keys for clear user guidance. The operator starts the process by pressing the formulation soft key to access the recipe database. Fast filling preferred A color bar graph indicates filling status. Green means the operator has reached the pre-defined tolerance range and can continue with the next ingredient. Less waste If too much of one ingredient is added, the operator can simply press a key. The software automatically recalculates the recipe and guides the operator through adjusting the other ingredients to save the batch. 4

5 Reduced waste A graphical bar on the screen gives clear feedback on the actual dispensing status. In case an operator adds too much of a single ingredient, the system can recalculate the amount of other ingredients required to let the operator adjust the recipe. Choosing a scale with an appropriate weighing range further reduces waste. If required, ICS689 terminals also allow up to four platforms to be attached. By simply pressing a button, the operator can shift from bulk to fine ingredient weighing. This speeds up batching and reduces waste. Safety and traceability Material data and batch numbers can be entered for each ingredient. When working with a barcode reader, the system can be configured to reject ingredients with the wrong barcode. It can also stop the process any time a weight is outside the acceptable range. All recipe changes and manual overrides are tracked in the database, and details of each mix can be output to a printer, memory stick, or PC for archival records. Flexible and mobile All ICS6-series bench scale models can be equipped with WLAN technology. In combination with an optional built-in rechargeable battery, these scales can easily be moved and placed where they best fit into your production operations for fast, safe formulation that meets your recipe requirements. `` Learn More The ICS689 formulation terminal features: Storage of 50 recipes 50 ingredients per recipe Overfill correction functions Horizontal or vertical batching Terminal facts: Color TFT display Scratch-resistant keypad IP69k protection Four attachable platforms Learn more about 5

6 Metal Detection How to Overcome Product Effect Robust Detection Avoids False Rejects A phenomenon known as Product Effect has long been an obstacle to attaining high levels of metal-contaminant detection sensitivity in the processed and packaged food industry. For many years, manufacturers have been forced to compromise on detection standards however, the advent of Multi-Simultaneous Frequency (MSF) means the challenge can now be overcome. Achieving optimum levels of metalcontaminant detection when inspecting packaged or processed foods can be difficult. This is because product characteristics can inhibit the metal detector s ability to distinguish the product from a metal contaminant. This phenomenon is known as Product Effect. Factors contributing to this phenomenon include moisture or salt content, temperature and product size or consistency. difference that causes the product to disturb the magnetic field in the aperture in the same manner as a metal contaminant. Items such as fresh meat, cheese and bread, have a high moisture content and are relatively good conductors. This makes them difficult to inspect as they are likely to produce a signal in the metal detector in the same way a small metal contaminant would. This makes it more difficult for the detector to distinguish between the product and the contaminant. This often leads to high levels of false rejects, which has a negative impact on Overall Equipment Effectiveness (OEE). Product effect explained Metal detectors are precision instruments designed to detect very small metal contaminants in much larger products. Other materials, such as water or saline, have the ability to conduct electricity and generate magnetic fields. In real-life applications, the volume of the metal contaminant is many hundreds or even thousands of times smaller than the products that are being inspected, and it is this volume Profile Advantage technology is ideal for inspecting challenging applications such as packaged foods with high mositure content or variable temperature 6

7 Overcoming product effect There is always a trade-off between product effect, maximum operating frequency and metal detector sensitivity. Previously, the solution to overcoming product effect was to reduce the sensitivity of the metal detector, but that resulted in smaller contaminants going undetected, increasing the risk of costly product recalls. Multi-simultaneous frequency A better alternative is to use a metal detector that uses MSF to overcome the effect. Profile Advantage advanced metal detectors from METTLER TOLEDO use a combination of high and low frequencies simultaneously with product signalsuppression technology to effectively remove the product signal. The result is an ability to detect significantly smaller metal contaminants while virtually eliminating costly false rejects. Easy set-up In addition to overcoming product effect, Profile Advantage detectors offer an auto-set up feature that reduces the time required to change settings between production batches providing increased process efficiency and productivity. `` Free Download Find out more about product effect Our white paper, Understanding Challenging Applications for Improved Metal Detection, examines how product effect can be overcome to find smaller metal contaminants in challenging applications. Free download 7

8 Laboratory Automation Degrees of Automation Save Time for What Really Matters Automation systems free researchers and technicians from repetitive manual tasks, allowing more time for actual science. In addition to making laboratory life easier, safer and healthier, automation helps to enhance data integrity and reproducibility. METTLER TOLEDO offers advanced automation solutions based on modularization and flexible integration with LabX software. This is achieved by distinguishing between single-sample and multiple-sample automation solutions, allowing you to decide when and how much to automate. 8

9 Single-sample automation Multiple-sample automation Single-sample automation systems are auxiliary devices and internal functions that automate certain parts of an analysis. In multiple-sample automation, several samples are measured in series, uninterrupted by manual steps. One Click Simply start the method via the shortcut on the touchscreen. LabX software Bring power to your laboratory bench with automatic data handling, high process security and full SOP user guidance. Barcode scanner and SmartCodes Just scan the barcode to easily identify your sample. SmartCodes automatically activates the correct method on the titrator or density meter. InMotion autosampler Skip manual steps with high capacity InMotion autosamplers, which are capable of analyzing over 300 samples. SmartSens XPE analytical balance with SmartSens. Draft shield opens automatically with the wave of a hand. Quantos Quantos combines powder and liquid dispensing technology with METTLER TOLEDO high-end balances for fast, safe and economical powder weighing and solution preparation. 9

10 X-ray Inspection Food Safety Assured X-ray Systems Deliver the Best Solution For one of Canada s leading nutrition-product manufacturers, quality is the hallmark of its brand promise. That s why it has chosen advanced product inspection equipment to ensure premium quality and protect the integrity and reputation of its highly respected brand portfolio. Canada s Riverside Natural Foods makes some of North America s most well-loved and respected cereal products. It has a reputation for top product quality and brand integrity. MadeGood allergen-free granola bars are a big seller, as are the bar s bite-sized minisnack versions. Given the MadeGood brand s wholesome reputation, the Company is ultra-keen to protect these and other Riverside products. Five systems become seven The company acquired five METTLER TOLEDO Safeline X33 X-ray inspection systems, which deliver outstanding contamination detection for packaged goods. Vice President of Operations Justin Fluit is confident in their ability to ensure optimal product safety and quality control. The x-ray systems are invaluable for detecting contaminants, such as metal, glass, mineral stone and pebbles bigger than two millimetres, he says. Food safety is a major critical control point for us, and these units have worked so well that we recently decided to purchase two more, making it seven X33s in total. Return on investment Fluit regards the X33s as world-class, describing them as very reliable, highly accurate and very flexible, so we can use them on bars, mini-snacks and wherever else is needed. Moreover, he adds, They can pick up things like fruit pits and nut-shell fragments that conventional metal detectors cannot detect, which provides real peace of mind. Fluit also regards Riverside s investment in the X33 detectors as an excellent move, as not only are they able to detect contaminants, but they can also perform gross-mass measurement for calculated portion control while ensuring product integrity. The X33 can also be used to inspect finished multipack products. Lower power requirements The systems use five times less power than other X-ray systems and the X33 s flexibility and modularity reflect Riverside s ambitious business plans. If you want to attract bigger customers, you need to show that you have the best equipment to ensure that your product is as safe as it can be, Fluit says. `` 10

11 Watch Video Free Download See for yourself Watch a short video and see how the healthy snack manufacturer Riverside Natural Foods Ltd. enlisted the help of a METTLER TOLEDO Safeline X-ray to carry out contamination detection and quality control for its customers with the X33 Series. Watch the video More than contaminant detection X-ray Inspection More Than Just Contamination Detection, explains how x-ray inspection systems are capable of identifying many quality shortfalls that lie deep within products or hidden within their packaging. Free download 11

12 Get the Most Out of Your Weighing Equipment 5 Ways Food Manufacturers Can Improve Efficiency Did you know that by using the right weighing equipment at the right stage in the production process, you can speed up your processes, achieve higher product quality and improve equipment uptime? The graphic below illustrates how. 1 Speed up checkweighing from manual to fully automated checkweighing 2 Grow with your needs by using statistical quality control 3 Reduce the risk of recalls and optimize label control 5 Improve uptime in tank weighing with predictive maintenance and condition monitoring 4 Speed up filling processes and select the right weighing method Download Quick Note ` ` METTLER TOLEDO Group Industrial Division Local contact: For more information Subject to technical changes 02/2018 METTLER TOLEDO. All rights reserved Document No MarCom Industrial