Specialty Chemicals. News. Chemistry, the fabric of life

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1 Specialty Chemicals For a better living News Chemistry, the fabric of life 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. 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 complete weighing and measuring solutions that enhance your high standards even more. What are your benefits? Up to 100% uptime Full safety in hazardous areas Highest accuracy & reliability Complete chemical resistance 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. 1

2 Contents How a flavors & fragrances manufacturer «makes the world smell better» ATEX137 countdown are you ready? Made for very bad weather, too How a flavors & fragrances manufacturer «makes the world smell better 1» 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? 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 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 business, it s an art. Imagine a group of dedicated individuals charged with the mission to make the world smell better 1. And this is why a well-known flavors & fragrances manufacturer made the slogan his credo. Our customer has over 180 years of experience and a global team of 70 perfumers creating the world s most memorable 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. METTLER TOLEDO helps to «make the world smell better 1» 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 MTSI 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? 1 makes the world smell better is a Givaudan trade mark 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, successful 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. 2 METTLER TOLEDO

3 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 In order to accomplish the high quality benchmark, and to combine all necessary ingredients for a tasty, flavoryrich product for drinks, yoghurts, cookies, etc. they use a manual filling system in each of the 8 filling stations with a supportive 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 Customer key benefits Exact formulation due to reliable, repeatable and accurate weighing equipment Suitability for hazardous areas 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 capacities. 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. Three platforms connected to one weighing indicator Withstands harsh conditions Easy to clean design All-in-one solution 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 d Certified resolution up to 35000e Specialty Chemicals News 3

4 ATEX 137 countdown are you ready? Of the 120 million workers within the EU, every year 10 million are the victim of the work-related accidents or disease and die. (Source: Over the past 30 years, the need to improve conditions in working places has been one of the European Commission s primary objectives. One of these ATEX 137 (EC 99/92/EC) is currently in transition phase, becoming fully effective from July (Germany from January ). Where are you in this transition phase? All your equipment is ATEX 95 certified You still have some non-atex 95 certified equipment running You are ready Your explosion protection document requires you to performa arisk assessment of such older equipment You perform a thorough risk assessment and analyze potential ignition sources of your older equipment. That includes electrical as well as non-electrical (mechanical) parts. You replace with ATEX 95 certified equipment You replace such equipment with ATEX 95 certified equipment and transfer the responsability to METTLER TOLEDO You assume responsibility of the older equipment You are ready You are ready Total safety in hazardous areas with METTLER TOLEDO + = Ex Total hazardous area safety 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 scales Scale 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 rotating 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. 4 METTLER TOLEDO

5 Made for very bad weather, too Fast Facts: MTX digital load cells 5 year warranty Over Installed worldwide 25-90t / lbs Instant failure notification IP68/IP69K 3000e e 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 Snow & Cold Mud & Ice Desert & Heat Lightning Water & Flood Peace of Mind MTX POWERCELL 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 Mud, snow, water and lightning routinely 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 discovered 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 introduction 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 maintenance 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! Specialty Chemicals News 5

6 Predictive maintenance triggers healthier profits As 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. If maintenance in predictive manner equals, for example, $1000, then preventive costs equals $5000 and reactive maintenance equals $ But, if you actually end up with an unplanned shutdown, then you d be looking at >$40000 for costs. Stuart Harris, Emerson Process Management 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 unnecessary 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 Today s maintenance practice Reactive = Fixing or replacing equipment after it fails Preventative = 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 parameters 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 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 6 METTLER TOLEDO

7 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 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 polymerization 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 components are mixed (agitator) 6 The finished batch is discharged to the storage tank Superabsorbent polymers are materials with the ability to absorb and retain large volumes of water and aqueous solutions. The weighing indicator (JagXtreme) acts as a slave sending weight data over the Allen Bradley RIO interface to the Rockwell ControlLogix PLC Storage Tank 6 Mixing Tank 2 3 Low level sensor High level sensor Allen Bradley RIO Flexmount Weigh Module RAAD Box JagXtreme Indicator Specialty Chemicals News 7

8 METTLER TOLEDO Solution 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 Load Cells, Scale bases RAAD-Box JagXtreme Indicator 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 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 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 JagXtreme & RAAD Box the first weighing solution that employs predictive failure analysis High performance maintenance with TraxEMT turns strain gauge load cells into intelligent sensors: Monitors the condition of each individual load cell and predicts failures before they occur: Alerts designated individuals of potential failures or maintenance needs by /sms, so that a defective load cell can be replaced, guarding you against costly downtime or product waste On load cell failure, «Run Flat» technology allows to continue production runs until the load cell can be replaced Total maintenance Schedules and tracks maintenance Notifies maintenance checks via 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 8 METTLER TOLEDO

9 Smart IND130 Direct to destination without detour Load Cells, Scale bases IND130 Connect your analog load cells over: Profibus DP Allen-Bradley RIO RS232...directly to your PLC or DCS for batching, filling, tank/hopper weighing, and for inventory control without detouring dataflow 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 environments. Are there any side effects? No, only positive ones. PLC 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! PC, DCS 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 ( Hz) Cutoff corner frequency ( Hz) Notch and stability filter Specialty Chemicals News 9

10 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 Average time to record data per chart h 8 5 Average time for chart calculations h (automatic) Average hourly costs for line operator USD Total time preparing charts h Monthly costs to prepare charts USD Your savings generated through the implementation of FreeWeigh.Net Monthly savings USD Your Return on Investment Initial Investment 33 x ID30 Weighing PC FreeWeigh.Net software network Uplink modules Bench scales USD ROI Months 3.19 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 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 10 METTLER TOLEDO

11 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 collaborate in the weighing systems business. METTLER TOLEDO products are jointly certified to work with SIWAREX weighing controllers. METTLER TOLEDO manufactured analog weighing platforms and compact scales can be directly connected the Siemens PLCs via SIWAREX. METTLER TOLEDO offers weighing capacities from 3kg up to several tons in both general purpose 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 PLC Load Cells, Scale bases 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 equipment uptime, traceability of results, and regulatory compliance. ServiceXXL Solution Expert validation support Manufacturer developed Validation Protocols Software Update & Maintenance Agreements Industry specific Equipment Qualification Packages Equipment re-qualification Factory trained and authorized technicians Calibration Report ISO Calibration Certificate ISO 9000 Certification of measurement uncertainty and MinWeigh Service Agreements Installation & Repair Customer Training & Seminars Application & Technical Support Service Center Validation Qualification Calibration Maintenance & Support Customer Value Validated Methods ensure 21 CFRPart 11 Conformity Monitored user management Safe data mangement Conformity with industry specific standards Avoidance of FDA warning letters and fines Limited start up costs Accuracy, reliability and traceability of measuring results Known measurement uncertainty Calculated minimum weight and activated MinWeigh warning function Control of unexpected expenses Optimized up-time & productivity Documented proof of user training Avoidance of contamination Service access from remote areas Specialty Chemicals News 11

12 Process Analytics. We re a leading supplier of analytical measurement solutions for the control of liquid production processes. The business unit INGOLD specializes in the parameters ph, DO, conductivity, turbidity and CO 2, providing 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. Literature Predictive Maintenance Keep your process up and running all the time 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 g 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 Hazardous Area Focus Where Safety comes first Weighing in the Chemical & Pharmaceutical Industry Synthesize your vision we help you measure it 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. Mettler-Toledo GmbH. CH-8606 Greifensee, Switzerland Tel Fax