Transcript
Beverages Industrial Weighing and Measuring
Efficient quality control using a smart compact system Located in Saint Sauvant, France, the Merlet et fils distillery was established in 1853. Until 1980 the business was based on the production of cognac and pineau. Diversification started when an American company asked for a cocktail called HPNOTIQ to be created. HPNOTIQ combines young cognac, vodka and tropical fruit concentrate. This drink is packaged in a champagne-type bottle, and nearly 13 million bottles of HPNOTIQ are shipped across the Atlantic. The production involves a complete singleproduct bottling station that handles a number of different bottle sizes: 20cl, 37.5cl, 70cl, 75cl, 1l and 1.75l. Merlet installed the new net content control system SQC16 from METTLER TOLEDO. Five empty bottles are collected randomly every hour from the production line, assigned an ID number and weighed. The SQC16 records this initial information. The bottles are then filled and weighed again. The scale, which has already
recorded the weight of the empty bottles, can now indicate the exact net weight and convert it to volume. Installing a statistical control system has dramatically improved the filling process – resulting in less overfill and improved profitability. With its ability to save and print data, the SQC16 ensures compliance with net weight legislation. The compact and robust design of the system meets the requirements set by the Merlet distillery. Jean Marie Sailly, Quality Manager at the distillery, acknowledges “the staff have quickly become comfortable with this scale because it’s very easy to use.”
1
News
Tank & Silo Weighing Solutions
Tank and silo weighing solutions master your batching processes Boost your productivity and process uptime with reliable weighing equipment – improved batching speed and precision, maximum uptime at low maintenance cost Fast, reproducible and reliable batching and filling are key success factors for your production process. Various factors can affect precision: foam can compromise optical/radar sensors, and solids do not distribute evenly in a tank or silo. Our weighing technology is not affected by these conditions and provides direct, accurate and repeatable measurement of mass without media contact. In addition
Key customer benefits
Increased precision and consistency of your material transfer processes Faster batching process through supreme TraxDSP™ noise and vibration filtering Minimal maintenance cost
SCADA
Controller
Fast facts weighmodules Flexmount™/Flexmount™ HD
Stainless steel load cell Accuracy: 3000d OIML version and 3000d, 5000d, 6000d and 10 000d NTEP versions (depending on capacity) Flexmount™ capacity range from 220kg to 20 400kg Flexmount™ HD capacity range from 22 000kg to 90 000kg Anti-lift device prevents tank from tipping For light capacity applications choose Ultramount™ capacity range from 5kg to 100kg
Publisher Mettler-Toledo GmbH Industrial Sonnenbergstrasse 72 CH-8603 Schwerzenbach Switzerland Production MarCom Industrial CH-8603 Schwerzenbach Switzerland MTSI 099713 Subject to technical changes © 05/2006 Mettler-Toledo GmbH Printed in Switzerland
2
our range of terminals and transmitters/sensors enable easy connectivity to your control systems.
METTLER TOLEDO
Beverages News
Fast facts terminals/transmitters PTPN and IND130
Exclusive TraxDSP™ vibration rejection and superior noise filtering system Easy data integration through a variety of interfaces, including Serial, Allen-Bradley® RIO, Modbus Plus®, Profibus®DP and DeviceNET IP65 stainless harsh versions
or
IND130 weight transmitter
PTPN process terminal
Process terminal PTPN
Local display for weight indication and calibration checks Panel-mount or stainless steel desk enclosure
IND130 smart weight transmitter
TraxDSP™ noise and vibration filtering
Direct connectivity where no local display is required Quick setup and run via PC tool CalFREE™ offers fast and easy calibration without test weights DIN rail mounting version
Flexmount™ weighmodule
Consistent flavor and quality through total recipe control Innovative flavours and product consistency are key to differentiate from competition. The METTLER TOLEDO FormWeigh.Net® system combines efficient, powerful formulation software with reliable weighing technology. The perfect mixture is essential for product quality. First class beverages require not only premium raw materials but also total process control. To produce the same perfect quality every time, the line operator needs support from an ideal recipe system – FormWeigh.Net®. This system provides important parameters such as materials, recipes, operator instructions and raw material information at a click of the mouse. FormWeigh.Net® guides the operator securely and quickly through the daily formulation work. It provides all necessary information electronically
in the central production area. Due to the simple and user-friendly screen layouts the operators are able to work efficiently and accurately, even after a minimal training period. The production process is documented and every single work-step is registered in the database. Tracing production history is no longer a hassle for the quality or production manager. The required information can even be retrieved electronically in order to pass the data to a third party such as an auditor.
Key customer benefits
Accurate and reproducible quality Minimal waste material caused by bad batches Fast and accurate operation through simple, user-friendly screen layouts Full traceability and regulatory compliance Prevention of loss through automatic correction of ingredients Easy integration into data management systems (e.g. SAP)
Process analytical equipment for breweries Reliability even under demanding process conditions With INGOLD’s top of the line pH, oxygen and turbidity measurement solutions controlling the process, you can expect improved beer quality, simplified maintenance procedures and reduced process costs. Optimal quality assurance with dissolved oxygen measurement
Taste, clarity and long shelf life are critical quality measurements in nearly all beer production processes. On-line measurement of dissolved oxygen concentration in fermentation, storage tanks and transfer points ensures an optimized control of fermentation processes and hence taste. A low oxygen concentration, less than 50ppb, is essential for a long shelf life in bottles, kegs or cans. On-line dissolved oxygen (DO) measurement at lowest concentrations is possible with INGOLD DO systems – even under the most demanding conditions
at the filler line, our DO measurement system helps ensure the quality and long shelf life of the beer. Turbidity measurements – when clarity matters most
Turbidity measurement is essential for quality assurance and process optimization, starting with lauter tun control in the brew house down to filter breakthrough detection and quality control at the filler line. INGOLD now offers this technology as a complementary part of the METTLER TOLEDO instrumentation solutions portfolio for breweries.
For direct installation in pipes InPro 800 turbidity sensor
Versatile and user friendly M 700 pH and DO transmitter
METTLER TOLEDO
Beverages News
3
Statistical Quality Control
Fulfill average weight legislation and reduce costs Accurate monitoring of portions and final product weight is essential for controlling material use and fulfilling net content legislation. Solutions from METTLER TOLEDO for statistical quality control combine ease of operation, quality data management and analysis functionality. Sampling of fill quantities for liquid or powder products allows precise adjustment through operator prompting or closed loop control to the filler from a dynamic checkweigher. Unnecessary material losses are
avoided and legal fill quantities and average weight regulations are met. Production processes conform with internal and external standards such as ISO and GMP. Our standalone compact solutions or networked systems provide statistical data to understand, document and control profitability and quality.
Key customer benefits
Save money by reducing overfilling Avoid legal complaints Simple and informative online status of filling process, allowing quick reaction Streamline internal QA procedures
Package quality parameters
Product quality parameters
Cap torque OK? Sealing OK? Fill level OK? Label OK? Undamaged? Net content OK? Expiry date OK? Batch/lot ID OK?
Sensory test Visual appearance (colour...) CO 2 O2 Moisture Turbidity pH-value Metal free?
Typical FreeWeigh.Net screens
Solutions that pay back!
METTLER TOLEDO
Beverages News
Parameters
Value
Unit
Raw material costs
1.–
US$/kg
Packages produced
100,000
Units per day
Nominal fill quantity
100
g
Production days
250
Days per year
Production mean value
101
g
Overfill per package
1
g
Overfill per day
100
kg
Overfill per year
25,000
kg
Overfill losses
25,000.–
US$/year
?
Compact solutions: SQC14/SQC16 – eliminate pencils and pocket calculators Sample check your products on our entry level portable compact system for efficient net weight control: Flexible for up to 300 articles Statistical analyses and graphical representations
Handwritten test report
Long-term and batch statistics Keyboard and barcode reader interface Trend analysis with alarms
PC-based/networked solutions: FreeWeigh.Net® – total quality control for quality products Our expandable networked system ensures maximum networked protection and connects to virtually any device for instant data collection and analysis of important process parameters: Powerful quality assurance system for all aspects of product and package quality control Statistical quality data is evaluated online on the display screen or in freely definable reports
Devices are linked by Ethernet/ TCP/IP, data stored on MS SQL database
Batch report with standardized data analysis
ID30 with FreeWeigh.Net® monitoring screen
Sample check
Hi-Speed checkweigher
Safeline® metal detector
Efficient average weight control that pays back quickly Sill, a French food and beverage company located in Brittany, uses net weight control to reduce overfilling costs substantially. Using their expertise in producing UHT and fresh products, Sill developed their product range over time from milk and butter fabrication to fruit juice, soup manufacturing and ready meals. The daily output of fruit juice and soups at their factory in Plouvien accounts for 500 000 liters. In the field of fruit juice Sill manufactures nectar, pure juice and juice based on concentrate. Flavors vary from apple, orange, and grape to mixed fruit juice. Rugged and easy to integrate net weight control
Rémy Raguenes, net weight specialist at Sill, explains: “Before we installed
the net weight control system, overfilling was not under control. Due to the installed weight check points along our filling lines, we are now able to control the overfilling in an easy to operate way: If the targeted weight is not met the operator receives realtime information about the need to adjust the filling machine.” Each of the sample check points installed consists of a full stainless steel IP69k ID7 weighing terminal and a KA15s platform connected via Ethernet to the FreeWeigh® system. The weight data sent to the system are stored in the Microsoft SQL database and statistically analyzed for further use by the quality manager.
Short payback time
The system provides permanent online information and increases the awareness of the filling precision. Mr. Raguenes summarizes: “The FreeWeigh® system enabled us to reduce overfilling substantially which resulted in a payback time of only six months.“
METTLER TOLEDO
Beverages News
5
Vehicle Weighing
Full control of inbound and outbound goods with reliable vehicle weighing METTLER TOLEDO manufactures a wide range of vehicle and rail scales designed to meet your specific requirements. Our OverDrive® vehicle management software creates a comprehensive and simple-to-use material monitoring package, providing full transparency into inbound and outbound material flow. Treating yourself and your customers fairly is dependent on 100% accurate weighing. A damaged sensor could cause your scale to register incorrect weight. The METTLER TOLEDO MTX POWERCELL® tells your operator in seconds that you are at risk to lose money or valuable customer relationships. In addition, the MTX POWERCELL® is resistant to lightning, can be submerged, and now is the first digital vehicle scale
cell rated both IP68 and IP69K. A routine maintenance plan keeps your METTLER TOLEDO scale operating at top performance, reducing the total cost of ownership. Key customer benefits
Optimized plant efficiency with transparent inbound and outbound material control Extremely low failure rate through a rugged and reliable solution Fast and precise shipment completion
MTX POWERCELL®
OverDrive®
Guaranteed service Keep your business running Avoid unnecessary downtime with our wide range of service packages. With a range of innovative service solutions offering regulatory compliance, equipment calibration, training, routine service and breakdown assistance, you can profit from sustained uptime,
6
METTLER TOLEDO
Beverages News
together with ongoing performance verification and long life of equipment. There is a range of contract options designed to complement your existing quality systems. Each one
offers its own unique set of benefits depending on the equipment and its application.
Checkweighing/foreign body detection/X-ray 100% control for high speed filling Cornerstone™ Beltweigh/CM/Combo checkweigher provides metal detection and checkweighing in one unit. The Beltweigh/CM/Combo achieves superior weighing accuracy by using high-performance servo motors that minimize vibration. Furthermore, it incorporates Hi-Speed‘s patented DSP noise-filtering system, which further enhances weighing accuracies, especially in high-throughput applications. The operator interface displays statistical data of up-to-the-minute production information and performs extensive self-diagnostic checks to help ensure maximum up-time. The Safeline metal detector is designed to
provide protection against all types of metal contamination. The metal detector is microprocessor based and uses digital signal processing to ensure simplified setup and optimized detection capabilities. Safeline X-ray-inspection
Ideal for identifying non-metallic contamination, X-ray inspection systems provide the optimum protection for your products, your customers and the reputation of your brands.
Surveyed keg filling by effective sample checking Sample check weighing used to fulfill net content legislation. Brewing high quality ales demands experience in combination with the latest production and cutting-edge packaging technology. METTLER TOLEDO UK equipped a keg filling line (capacity: 450 kegs per hour) with an integrated filling control system. Surveying the precision of the filling process with regard to the net content is essential to comply with legislation. The keg filling accuracy is controlled by sample checkweighing supplied by METTLER TOLEDO. Additionally there are weigh stations to identify the tare of the empty kegs. After the filling process, keg samples are randomly chosen, weighed and pushed back into the process if the weight meets the tolerance. Failed kegs are rejected and fed back to the filling step.
Two scale bases integrated under driven conveyors and JagXtreme® process weighing terminals fulfill the needs for successful net content control. The terminals are equipped with I/O controlling the conveyors and Ethernet interfaces for data transfer with a higher-level system. Due to the efficient and easy-to-use sample checkweighing, the balancing act – required to satisfy the weights and measures authority (no underfilling) and the Customs and Excise authority (no overfilling) – is no longer a hassle.
METTLER TOLEDO
Beverages News
7
A wide range of solutions to improve processes 1. DL22 Food and Beverage analyzer 2. DL50 titrator with Rondolino 3. Halogen moisture analyzer 4. Barcode readers, form-/label printers
4
1
2
3
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 beverage 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.
1. Statistical Quality Control/Statistical Process Control 2. FormWeigh.Net® – Formulation/recipe solution 3. Process weighing 4. Predictive maintenance
1
2
USA Mettler-Toledo, Inc. 1900 Polaris Parkway Columbus, OH, 320 Tel. (1) 800 523 5123 Your METTLER TOLEDO contact:
3 Canada Mettler-Toledo, Inc. 619 Northam Drive Mississauga, Ontario, LV 1J2 Tel. (1) 800 523 5123
4 Mettler-Toledo GmbH Sales International CH-8606 Greifensee Switzerland Tel. +1 9 22 11
www.mt-learnmore.com/us-beverage-1 For more information
