Table of Contents

1 Introduction………………………………………….………………………………………………………..…… .4 2 What is a checkweigher………………………….…………………………………………………………..…5 2.1 Belts of a checkweigher………………………….…………………………………………………………..…6 2.1.1 Infeed belt………………………….……………………………………………….……………………………..…6 2.1.2 Reject belt………………………….……………………………………………..………………………………..…6 2.1.3 Weigh belt………………………….………………………………………………………………..……………..…6 3 Uses of a checkweigher…………………………...…………………………………………………………..…7 3.1 Regular………………………………………………………………….…………………………………..…………..7 3.2 Statistical………………………………………….………………………………………...……….………….…..…7 4 Importance of checkweighers…………………………………………………………………………………8 4.1 Keeps Brand Secure……………………………………………………………………………………………..…8 4.2 Meets Regulatory Norms……………………………………………………………………………………...…8 4.3 Improves Plant Efficiency………………………………………………………………………………………8 4.4 Enables Proper Weight Control……………………………………………………………………………….8 4.4.1 Meet Specifications………………………………………………………………………………………………...8 4.4.2 Underweight Net Content…………………………………………………………………………………….…8 4.4.3 Overweight Net Content…………………………………………………………………………………………9 4.4.4 Contaminants…………………………………………………………………………………………………………9 4.4.5 Missing Elements……………………………………………………………………………………………………9 4.4.6 Classification…………….……………………………………………………………………………………………9 4.4.7 Control………………………………………………………………………………………………………………..…9 4.4.8 Dismal Products…………………………………………………………………………………………………..…9 4.4.9 Lot Deviation……………………………………………………………………………………………………….…9 4.4.10 Missing Secondary Components…………………………………………………………………………...…9 5 Regulatory Norms on Net Contents…………………………………………………………………………9 6 Legal Actions Against Erring Companies………………………………………………………………….9 7 How does a checkweigher work…………………………………………………………………………….10 7.1 How a checkweigher weighs products…………………………………………………………………..10 7.2 Movement of Products ….………………………………………………………………………...... ……...... 10 7.3 Rejection of Products…………………………………….……………………………………...... 10 8 Weighing Accuracy……………………………………………………………………………...... 11 8.1 Checkweigher Accuracy……………………………………………………………………………...... 11 8.2 Importance of Weighing Accuracy…………………………………………………………………………11 8.3 Ways to Achieve Weighing Accuracy……………………………………………………………………..11 9 Difference between an Automatic Checkweigher and a Static Scale….……………………..11 10 How to keep the checkweigher performing to its best……………………………………………12 10.1 Belts and chains……………………………………………………………………………………………………12 10.2 Mechanical alignment…………………………………………………………………………………………..12 10.3 Rejectors and photo eyes……………………………………………...………………………………………12 10.4 Transfer of products…………………………………………………………….………………………………12 10.5 Product separation……………………………………………………………………………………………….12 10.6 Calibration…………………………………………………………………………………………………………...12 10.7 Product specifications…………………………………………………………………………………………..13 10.8 Grey Zone Check…………………………………………………………………………………………………..13 10.9 Reports…………………………………………………………………………………………………………...... 13 10.10 Alarms………………………………………………………………………………………………………………....13 11 Do’s and Don’ts of Checkweighers…………………………………………………………………………13 11.1 Do’s of checkweighers………………………………………………………………………………………..…13 11.2 Don’ts of checkweighers……………………………………………………………………………………….13 12 Types of Packages………………………………………………………………………………………………...14 13 Customizing a checkweigher…………………………………………………………………………………14 14 Multi-Lane Checkweigher Solutions Are Efficient…………………………………………………...14 15 IP65 Washdown Requirements…………………………………………………………………………..…15 16 How To Check Whether A Checkweigher Is In Top Condition…………………………………15 17 How To Choose A Reliable Checkweigher………………………………………………………………16 17.1 Solutions that match the problem accurately…………………………………………………………16 17.2 Do not avoid problems…………………………………………………………………………………………16 17.3 Value instead of mere attractive features………………………………………………………………16 17.4 Best technology provider…………...…………………………………………………………………………16 17.5 Great in promise and delivery both……………………………………………………………………….17 17.6 Quality and security……………………………………………………………………………………………...17 17.7 Avoid generalists………………………………………………………………………………………………….17 17.8 Checkweigher literature……………………………………………………………………………………….17 17.9 Living up to the promise………………………….……………………………………………………………17 17.10 Ease of use………………………………………………………………………………...…………………………17 17.11 Display functions……………………………………………………………………………………………….…18 17.12 Ease of connectivity…………………………………………………………………………………………...…18 17.13 Fieldbus network needs……………………………………………………………………………………..…18 17.14 OPC Requirements…………………………………………………………………………………………….…18 17.15 Fill quantity checking……………………………………………………………………………………………19 17.16 Product handling………………………………………………………………………………….………………19 17.17 Additional weight zones………………………………………………………….……………………………19 17.18 Data security…………………………………………………………………………………….…………………19 17.19 Traceability…………………………………………………………………………………………………………20 17.20 Data handling flexibility…………………………………………………………………………….…………20 17.21 Secondary functions…………………………………………………………………….………………………20 17.22 Statistics functions…………………………………………………….…………………………………………20 17.23 Program details……………………………………………………………………………………………………20 18 Checkweigher feedback system……………………………………………………………………………..20 19 Data management on cloud and its analysis…………………………………………………………...21 20 Checkweigher Market Trends………………………………………………………………………………..21 20.1 Strain gauge technology-based automatic checkweighers will become popular………21 20.2 EMFR technology-based automatic checkweighers will grow better in global market ……………………………………………………………………………………………………………21 20.3 Pharma industry will register the highest demand for automatic checkweighers…….21 20.4 APAC will be the fastest-growing market for checkweighers…………………………………22 21 Future of checkweigher……………………………………………………………………………………...22 References………………………………………………………………………………………………..…………………………233

3 Introduction

A checkweigher is one of the most important elements of the production process. It helps you with ensuring regulatory compliance, improve productivity, increase profits, avoid costly product giveaways, and meet consistent results. Prompt Equipments brings to you this white that explains how a checkweigher can simplify your production process and bring you better profits.

In this white paper, we address the advantages of checkweighers, their varied uses, working pattern, and tips on selecting the right checkweigher for your business. We also take a look at the quality control aspects, issue of product giveaways, operational efficiencies, and product consistency.

With the advancements in technology, a checkweigher can help you understand in minutes if your products meet the specifications listed on the . These include product weight and components. Furthermore, production data helps you in making your processes efficient to achieve the highest standards.

Browse through this whitepaper to understand how a reliable checkweigher can give you quick and accurate packaging and achieve the desired results.

2 What is a checkweigher?

Checkweighers are systems that help in weighing items when they pass through a production line. They also classify items according to their predefined weight zones. When the items do not meet the defined classifications, checkweighers sort or eject them accordingly. A checkweigher will ensure that it weighs all of the items on a production line.

Many sections comprise a physical checkweighing system. They include scale section, infeed section, discharge section, computerized control, and rejector or line divider. It is common to have different checkweighers and components based on their usage. The other factors that influence the design of a checkweigher include the surrounding environment and the types of an item being weighed.

When it comes to an automatic checkweigher, there are a series of conveyor belts. These checkweighers are thus known as belt weighers, dynamic scales, conveyor scales, in-motion scales, and in-line scales. They are known as check scales in applications.

2.1 Belts of a checkweigher A checkweigher usually has three belts. Here is an overview of them:

2.1.1 Infeed belt: It changes the speed of packages if they need to be brought down or up to the desired speed for weighing. It also acts as an indexer to create a necessary gap between items that ensure optimal weighing distance. The positioning of items happens through special chains or belts.

2.1.2 Reject belt: When any package does not meet the tolerance levels, it gets removed from the conveyor through the reject belt. The reject function depends on the application as well. Heavy items require radial or linear actuators, while smaller products need only an air-amplifier to blow them away. In the of fragile products, they get dropped from the belt to slide easily into another conveyor or bin.

2.1.3 Weigh belt: They get mounted on a weight transducer. It can be a servo-balanced, strain-gauge, or split-beam load cell. In the case of old , the belt might get paused before the weight measurement. This directly affects the throughput and line speed.

When it comes to high-speed precision scales, EMFR (electromagnetic force restoration) load cell becomes relevant. When the inductive coil gets charged, the weigh bed gets floated in an electromagnetic field. Vibrating wire load cells and strain gauges are other technologies used here. To ensure an accurate weight reading, the built-in computer needs multiple weight readings from the transducer.

The next critical factor here is calibration. Lab products not in motion. When in motion, there scales can usually weigh objects with a are factors like vibration, air-conditioning, precision of 100th of a gram (+/-). However, noise from the belt, etc. Erroneous readings the readings might also depend on factors like also happen because of torque on a load cell. ambient air pressure. It is applicable for

3 Uses of a checkweigher

Checkweighers have become more accurate and reliable than ever because of technology. Earlier, it used to take a lot of effort to manually complete the quality check process. However, checkweighers make it easy today and finish the task in minutes. The biggest asset of any checkweigher is its ability to achieve complete sampling. This is much better as compared to offline sampling.

3.1 Regular There are several reasons to use a checkweigher on a regular basis. Here are some of them.

• Check whether a package is under or overweight • Check whether a package has all components like , instructions, , coupons, etc. • Ensure that packages meet compliance norms required for prepackaged goods • Check the count by weight to identify the missing , , can, etc. • Verify whether the solid to liquid ratio has established standards of weight limits • Ensure that packages meet agency and customer specifications • Avoid product giveaway with the help of checkweigher totals • Align products according to their weight grades • Check process performances by weighing packages before and after • Meet production line efficiency and regulatory norms

3.2 Statistical There are several reasons to use a checkweigher statistically. Here are some of them.

• Use total weight and total count to monitor production efficiency • Use weight zone or classification to check the production process • Use multiple zones to get complete fill weight information • Monitor the production speed efficiency of items • Maintain production records for regulatory agencies and management • Monitor standard deviation in case of out of tolerance conditions • Get production totals data for each shift, hour, or day • Use statistics to monitor short and long-term filler performance • Adjust processes and get manual feedback through Statistical Process Control (SPC) charts • Use SPC charts for automatic process adjustments, closed-loop control, and feedback

4 Importance of checkweighers

A checkweigher plays the role of a policeman on the packaging line of any production process. An effective weight control tool, checkweighers ensure that underweight or overweight products do not go out of the factory. Besides ensuring weight standards are met, a checkweigher also offers several other advantages.

4.1 Keeps Brand Secure If you want to protect your brand and improve its bottom line, delivering consistent quality products is crucial. It will directly help you in meeting consumer expectations. So you need to know that the weight mentioned on the product’s label matches the actual weight. A customer would not want to see a product with less than desired product weight.

4.2 Meets Regulatory Norms Packaging regulators and government agencies in India have laid the norms that every company must follow for their products. It becomes critical for every business in India to abide by the norms and ensure there are no discrepancies. Failure to do so often leads to a levy of heavy fines.

4.3 Improves Plant Efficiency The right checkweigher can help a business improve its equipment effectiveness. It is also possible to reduce product give-away through appropriate weight management. There are several other benefits like improved efficiency, consistent product throughput, and reduced rework.

4.4 Enables Proper Weight Control Checkweighers weigh products when they are in motion. Products get weighed, counted, and rejected if they do not meet the specifications. It helps in ensuring reliable weight control, meet legal requirements, and improve throughput. Having the right weight control has the following aspects.

4.4.1 Meet Specifications If you are wondering if the finished product matches the specifications, you should use the checkweigher to compare data within permissible limits. The reputation of your business can be at stake.

4.4.2 Underweight Net Content A checkweigher can ensure that you do not have underweight products. You will additionally meet the legal norms and compliances set by packaging regulators.

4.4.3 Overweight Net Content Product give-away can be costly and you need to avoid it. Checkweighers can ensure that only a specified amount of raw material goes inside each product, leading to a better bottom line.

4.4.4 Contaminants It is possible to combine some checkweighers with other inspection equipment. This includes X-ray systems or metal detectors for space-saving and economical inspection of products.

4.4.5 Missing Elements While the product weight is important, their count is also equally essential. It would not be a favorable situation if in a of 50 chocolates there are only 48 or 49.

4.4.6 Classification You can use a checkweigher to classify a product into grades and weight zones.

4.4.7 Control You can feed the weight data from your checkweigher into the filler system. It will lead to a closed-loop for better process efficiency.

4.4.8 Dismal Products A checkweigher can help you identify if a product got damaged, leaked, filled with the right number of elements, or if there is any foreign object inside the packaging. You can detect the problem before the product leaves the factory.

4.4.9 Lot Deviation Checkweighers monitor lots and compare standard deviations and averages to targets. This helps avoid discrepancies before your products get dispatched.

4.4.10 Missing Secondary Components There might be nut bolts, straws, or spoons with a product. A checkweigher can ensure that all of these secondary components also remain attached to the product.

5 Regulatory Norms on Net Contents

If there are any discrepancies found in the products during random checking and inspections, the company has violated legal requirements. In such cases, regulators call for strict action that includes penalties. If there are errors with one or two products in a lot, there might not be a strict punishment. However, if there are too many products with inaccurate weight, there could be heavy fines.

6 Legal Actions Against Erring Companies

Depending on the laws applicable in a particular jurisdiction, there can be several forms of legal action.

• Regulators might ask for reweighing or remarking of products. It means the company cannot sell the lot until they rectify the content on the product labels. • There could be stop-sale or off-sale orders, which prohibit the sale of those products. • There could be prosecution as well when regulators confiscate samples as evidence.

All of these legal hassles can be overcome with the intelligent use of a checkweigher. As there will be no underweight packages, the chances of consumer complaints are none. Furthermore, manufacturers can also benefit through the well-designed and maintained checkweighers that reduce product giveaways. They can reduce the average fill weight with the help of better accuracy and filling process feedback.

7 How does a checkweigher work

A checkweigher comes with a weigh frame and controller. A weigh frame has three basic sections.

• Weighing section • Infeed • Outfeed

7.1 How a checkweigher weighs products The weighing of products on a checkweigher is a four-step process.

• Products move from the outfeed onto the checkweigher infeed. The speed of the weigh table and infeed remain the same. • Products get weighed on the weigh table’s weigh cell. • Based on the checkweigher settings, products move to the outfeed of the checkweigher for acceptance or rejection. • When there is an ideal spacing between packages, maximum accuracy gets achieved through a zeroing operation.

7.2 Movement of Products Depending on the type of package, items move in three ways.

7.2.1 Belt: Packages move with the help of a motor. It ensures accurate movement of products.

7.2.2 Chain: Items get pulled forward with the help of a motor. It offers great sturdiness.

7.2.3 Skates: Packages get driven with a worm screw accelerator. It offers excellent performance in case of cans.

7.3 Rejection of Products Items can get rejected and removed from the conveyor in three ways.

• Pusher • Air blast • Bopper

Based on a specific package or customer reject requirements, packages can also get rejected in ways like:

• Drop flaps • Diverters

8. Weighing Accuracy

The hallmark of any checkweigher is its accuracy. There are several factors that can affect the accuracy of a checkweigher.

8.1 Checkweigher Accuracy Repeatability and linearity are the two essential factors that affect the success of a checkweigher. These also affect the accuracy of a scale. Linearity, in simple words, means the weighing capabilities of the checkweigher to weigh a package as accurately as possible each time a sample gets weighed on the scale.

When there is a difference between the indicated weight and the actual weight, it is an error. Systems with better linearity have the least errors. The average difference between the actual weight and the indicated weight is the mean error. The actual linearity of a load cell and perceived linearity has differences. Standard deviations help in measuring the repeatability of a system.

It is also essential to understand that the load cell linearity differs from checkweigher linearity. The checkweigher linearity is a statistical term in many ways. The variance gets calculated when a mass gets weighed repeatedly. A checkweigher can have better precision and repeatability when the standard deviation is lower.

8.2 Importance of Weighing Accuracy Weighing accuracy is important for three reasons.

• Your business must adhere to regulatory norms • Your products need to have accurate quantity of product they purchase • Your profitability can take a hit if there is excess product giveaway

8.3 Ways to Achieve Weighing Accuracy It is possible to achieve weighing accuracy when a checkweigher has a proper design with great detailing for factors like:

• Product size and weight • Product speed • Transfer of products from and to the checkweigher • Reject mechanism and design

9. Difference between an Automatic Checkweigher and a Static Scale

It is a common perception that it is easy to build a scale and many even try it. However, measures and weight certifications need to be accurate. It ensures that scales remain accurate and repeatable to their rating. Checkweighers differ from static scale as measures and weight regulations do not apply to them. This makes it difficult to identify a good checkweigher.

This can give businesses the freedom to claim the accuracy they want as there are no tough regulations on accuracy. They can also achieve the desired results by testing them the way they want. Most businesses that do not want to spend much on checkweighers go for a static base, an averaging indicator, a conveyor, and a photo-eye. But static bases are not usable for in-motion weighing. The cell can behave abnormally because of the dynamic loading and constant vibration of a package. It can often lead to a damaged cell or incorrect weighing.

Checkweighers need to be so accurate that they must get weight readings in no time. Static scales that have a traditional setup have longer settling times so they need not react quickly. It is not possible for averaging indicators to weighing items in motion as they have dynamic effects. Businesses need to ensure that they meet the regulations set for checkweighers. It thus becomes important for them to choose the right checkweigher manufacturers.

10. How to keep the checkweigher performing to its best To ensure that your checkweigher keeps performing accurately, you need to keep in mind the following things.

10.1 Belts and chains It is essential to check belts and chains regularly as there might be product buildup or wear and tear. You can replace them when needed. This can lead to inaccurate weights if the problem does not get addressed in time. Make sure you have a regular inspection schedule for cracks, wear, etc.

10.2 Mechanical alignment Ensure that the frame remains grounded at all times. The conveyors also need to be at a level and aligned to each other. The weighing process will not meet the desired results if the alignment is not proper.

10.3 Rejectors and photoeyes You need to check whether the photo eyes are operating correctly and in the proper position. Rejectors must work at the right time to reject inappropriate products into the bin.

10.4 Transfer of products Check whether products vibrate or jump when they get moved to the checkweigher. You also need to ensure that there is a proper gap between the conveyors at all times. It should not be more or less. When a product is stable, it will weigh better. The weighing table and infeed belts also need to run at the same speeds.

10.5 Product separation At any point in time, there needs to be only one product on the weigh table during the weighing process. If it is not the case, you will have to consider increasing the speed of the infeed.

10.6 Calibration You need to calibrate the checkweigher for span and zero. This needs to happen with and without the product. Whenever you are switching the product, you need to do the calibration. It is also advisable to do it on a daily basis. The production process needs to have enough gap so that the auto-zero routine gets adjusted.

10.7 Product specifications Make sure that you enter the weight and dimensions of the product correctly into the product recipe. The product specifications also need to be correct for the cutpoints for the underweight and overweight products.

10.8 Grey Zone Check Make sure that you had recently checked the calibration of your checkweigher. Whenever you shift or change a product, always do a grey zone check. It will help in ensuring that the checkweigher performs optimally each time. To get a valid result statistically, make sure you run a package at least 25 times.

10.9 Reports Reports need proper formatting as they need to accurately represent your production operations. This includes reports related to batch, shift, or lot information.

10.10 Alarms Ensure that you set the alarm conditions triggers properly. If your checkweigher has an alarm that goes often, it is most likely that operators will ignore it.

11. Do’s and Don’ts of Checkweighers

There are several things you should and should not do with a checkweigher.

11.1 Do’s of checkweighers • Calibrate it for each shift • Do smooth product transfers • Ensure appropriate tensioning of chain and belt of checkweigher • Choose only a reliable and accurate checkweigher for your production process • Do package spacing upstream and proper line configuration for better accuracy • When you request a quote for a checkweigher, provide all the customer and product- related information to the seller

11.2 Don’ts • Never go for the cheapest checkweigher available. If it needs frequent repairs, you might end up spending a lot more on it • Always avoid bringing conveyors in contact with the checkweigher • Avoid starting and stopping it frequently • Never run the line for more than an hour assuming that package gap will always remain autozero • Avoid the product buildup on load cell or weigh table • Keep adequate air pressure and poweraccording to instructions specified for the checkweigher

12. Types of Packages

There are several types of packaged items that you can weigh on a checkweigher.

• Dry items: rice, wheat, oatmeal • Soft items: paper, foil, plastic • Rigid items: cardboard, packages, cans, • Raw items: vegetables, fruits, fish, chicken • Wet items: dairy products, hummus

It is possible to weigh both food and non-food items like pharma products, of salt, cement, etc.

13. Customizing a checkweigher Customization is an essential factor that can help you maximize the process efficiencyfor reliable weight control. There are several factors that can deliver a customized solution.

• Types of chains and belts • Total number of weighing lanes • How do the weighing lanes get powered • Reject methods and devices • Belt speed • Vacuum infeed and outfeed • Availability of floor space

In the absence of a custom design, the weighing performance of your production process can deliver inaccurate results.

14. Multi-Lane Checkweigher Solutions Are Efficient

A multi-lane checkweigher can be beneficial in many ways for your business. With the help of a single-lane checkweigher, it is not possible to meet the filler capacity. You can also achieve better filler configuration outputs in the multiples of 2.

A multi-lane checkweigher offers several benefits like:

• Weighing accuracy: When there are lower packages per minute per lane, there will be an improved accuracy • Product handling: There is no need to shift from parallel to linear format • Cost: You canavoid multiple checkweighers and still handle extra products • Floor space: Linear space can get reduced to handle the package rate

15. IP65 Washdown Requirements

It is common for a checkweigher to come in contact with food products. These can often spill or leak, leading to contamination of the surface. It thus becomes important for the checkweigher to get washed down in order to prevent contamination. Checkweighers components need to have a tolerance to washing materials that can often have toxic chemicals. Here are some essential requirements for an efficient checkweigher.

• The material of the checkweigher should be made of stainless steel, one of the finest steels. This can be ANSI Type 304 SS. You can even opt for ANSI 316 for harsher environments. It is also more resistant to corrosion. • The checkweigher should meet the regulatory standards set by the national bodies. • The electrical equipment of the checkweigher also needs protection against foreign objects and water.

16. How To Check Whether A Checkweigher Is In Top Condition

The changing times have led to innovations in the packaging field as well. Eco-responsible packaging is on the rise as people can hold, use, repack them easily. However, this can affect the checkweighers adversely. A product with metal packaging will behave much differently than one with a flexible standup pouch. So you need to have a checkweigher that can switch seamlessly between different stations on the conveyor line.

Your checkweigher needs to have a consistent performance on the line. Multiple lines can have multiple products with varying requirements. The right communication from the checkweigher can track product lots. With the rising popularity of fresh food items, checkweighers get exposed to raw food. If the production line had canned packages previously, you might need to upgrade them for food items.

Instead of just having the last spot in the line, checkweighers need a location further upstream. It will help you in detecting problems and avoid them developing into bigger issues. It happens when multiple machines get placed at various spots along the production line. The language used by your production staff also matters. So make sure the checkweigher interface supports languages they understand. A checkweigher also needs to have a touch-screen interface for ease of use. Make sure your production staff will be able to work with this arrangement.

A checkweigher also provides the bells and whistles support. You can opt for that based on your needs. If you are only looking for a basic version, you can opt for additional upgrades later. Data storage is another aspect you need to look at. It is essential to store the data as it will be helpful if a problem arises later. A checkweigher is the last piece of equipment that touches a product on the production line.

If you are looking for advanced operations, you can even opt for real-time data. It will help you in checking production problems as and when they happen. You can avoid last-minute issues that can hamper the smooth functioning of the production process.

If space is a concern, you can opt for a combination checkweigher. It is possible to conduct your operations without the need for a big space. A combination checkweigher, when combined with a metal detector, can give you the desired weight control. You also remain assured that there are no foreign particles in the packages.

17. How To Choose A Reliable Checkweigher

Choosing a reliable and dynamic checkweigher is not by luck but by careful research and preparation. It is common for businesses to complain that the software and hardware of the checkweigher did not match their expectations. However, it can be often a result of the company’s fault. If a company does not have clear objectives or remains unaware of its requirements, problems are bound to arise.

In such cases, clashes can happen between the company and the supplier of the checkweigher. So business requirements and clear expectations need to be set upfront between both parties. When the business objective is clear and detailed, a checkweigher can give the desired results. If there are too many changes or back and forth, it could lead to a strained business relationship.

17.1 Solutions that match the problem accurately Application software and options often highlight the worth of an intelligent checkweighing system. For each business situation, a correct software application must get used. Companies need to specify their requirements precisely to get the best solutions. Furthermore, the seller also needs to have all the latest technologies available with them. This can be a win-win situation for both parties as a business would not feel shy in investing if they remain assured of results.

17.2 Do not avoid problems Quite often it can be a case where a business thinks that they can address a particular problem at a later stage and go ahead with buying the checkweigher. Be specific about the details and get answers to all your queries before you place the order. If the seller is able to respond fast and resolve all your queries, it can be a sign of reliability and trust. You can additionally ask for after-sales support to ensure there are no hiccups when you start using the checkweigher.

17.3 Value instead of mere attractive features The software must add real value to your business instead of only adding to the numbers. Just like any other electronic device, your checkweigher must give you multiple, value- based options. These options additionally need to be easy to understand and use. If that is not the case, these features will hardly be of any use. Customized applications can work wonders for your business. Keep in mind that some additional features might remain available at a lower price, but they also need to be of use for your production process.

17.4 Best technology provider The business world is ever-changing, which means you need to remain alert at all times. It is not necessary that what works for you today will also work tomorrow.Software applications keep on changing due to their dynamic nature. They also get outdated in a matter of time. So opt for service providers that have the latest technologies and offer regular updates.

17.5 Great in promise and delivery both Checkweighing systems are the hallmark of any modern packaging production line. A reliable and accurate checkweighing system can help you achieve your business goals. When opting for a checkweigher, keep in mind that quality, precision, and efficiency are very important. You would not want equipment that merely provides solutions. It also needs to affect and improve the bottom line of your business.

17.6 Quality and security Most modern checkweighers offer various weighing solutions today. Ithas become possible to completely weigh a production runkeeping in mind all the compliance factors. You can get comparative weight calculationsand regulation of filling machines. You can achieve this through weight deviations. This can also affect the production costs, quality, and customer satisfaction. You need to ensure that your requirements get implemented in the checkweigher software.

17.7 Avoid generalists You would want to avoid a supplier who has a solution for everything. It is advisable to opt for specialists who have done business with companies similar to yours in the past, along with a reliable track record. Production systems of today can lead to wear and tear of the checkweigher. So you need solutions that work to the best of their capacities at all times. You need an experienced supplier that has wide experience of dealing with problems that arise as a result of using such systems. Choose someone with whom you can work on a long-term basis.

17.8 Checkweigher literature The model you purchase needs to have comprehensive documentation about its working. It will help you find solutions to problems, especially when you are short on time. Documents should be made available to you both before and after purchasing the checkweigher. It will help you in your buying decision and also get after-sales support. Each supplier must have extensive documents that make it easy for their customers to understand more about the checkweigher. You can expect to receive such documents promptly from a reliable service provider. It will also be available in the language your employees are most comfortable with.

17.9 Living upto the promise The supplier might deliver many promises about the checkweigher. However, it is also important that they live up to that. You would want the results exactly as promised. It is often the case where sellers promise too much but fail to deliver. A service provider that has worked with many businesses in the past will have the necessary expertise and practical experience. A seller with expert knowledge will make the installation process easy and offer reliable support.

17.10 Ease of use The checkweigher should be reliable, simple, and easy to use. These are the essential qualities of a reliable checkweigher. So the control panel holds a lot of importance in such a scenario. You need to have a user-friendly interface that also meets the requirements of modern-day checkweighing. Your employees should be able to operate them without much hassle. Furthermore, a multilingual can be beneficial, especially if you operate from a rural area.

17.11 Display functions The user interface needs to have a simple design that is visible and easy to understand. There needs to be the option of multiple languages and a standard menu with essential functionalities. If you have multiple user profiles, it can become easy to make modifications to system settings and also enable product changeovers without much downtime.

If your production environment requires the wearing of gloves and working in poor lighting conditions, you also need to have the option of working the machine by wearing protective gloves. You might also need a checkweigher with some foreign characters. So opt for one that offers this function.

When you begin using the machine, you need to have quick access to all the essential checkweigher information. You can prevent production errors when you familiarize yourself with the user documentation. Make sure you get the documents that explain everything about the checkweigher in simple and clear terms.

17.12 Ease of connectivity Your checkweigher must get seamlessly integrated into the production line without any need for any modifications. Most modern checkweighersadapt to the existing production management systems, data protocols, and existing networks. It helps in avoiding integration costs and downtime. You need this function, especially if you have varied and complex manufacturing operations.

17.13 Fieldbus network needs ControlNet, Ethernet TCP/IP, and DeviceNet are the standard Fieldbus networks in the packaging industry. Most checkweigher manufacturers have standard interfaces for programmable logic controller (PLC) formats. It helps in the seamless integration of a checkweigher into the production line. When you decide to buy a checkweigher, ask the manufacturer about the PLC support. In most cases, they will have a mention the degree of integration in the interface manual.

You can establish a direct control in a Fieldbus network with the help of a PLC or any other controller. This can be done through a Supervisory Control And Data Acquisition (SCADA) or Distributed Control System (DCS) system. It is advantageous to use the DCS system as you need only one control module for every single machine operated via the Fieldbus network.

17.14 OPC Requirements OLE for Process Control (OPC) remains free from specific applications. It is an open connectivity standard interface that acts as a bridge between the hardware of the process controller and applications of Windows. It allows you to choose software and hardware without having to think about the proprietary drivers. The access does not depend upon data type and source. An OPC-compatible checkweigher will have a better interface connection to SCADA systems. It means that you can also get a cost and time advantage.

17.15 Fill quantity checking You would want absolute precision as every gram and milligram matter a lot. You can avoid overfilling by adding the exact quantity through an optimized fill quantity control system. It will also ensure maximum quality and consistent products. You can prevent losses, protect your brand, and ensure customer satisfaction.

If you want to avoid errors, you need to detect them in advance and take the necessary steps. It will give you consistent product quality, adherence to calibration specifications, and no underfilling or overfilling. With the help of the statistical interpretation of the weight distributions, you can regulate the filler to avoid material waste and product weight errors.

Environmental conditions can also affect product weight. Temperature and humidity can especially affect products with paper packaging. It is because of moisture absorption. In case of such fluctuations due to environmental influences, you need to have a checkweigher that can adjust itself by detecting the problem automatically. You can also overcome the problem of unwarranted rejections from the production line.

17.16 Product handling If you have a varied business, you will have products with different characteristics and influences. It can affect the production process. So you need stable solutions for your manufacturing process. You need to take care of all the finer aspects as well as complaints can arise because of them as well. A few missing elements from the final product can lead to the rejection of the entire lot. It could also lead to expensive reworking and scrap in some cases.

You need to have seamless solutions that ensure the quality of products matches the specifications. The checkweigher should also be able to detect and reject products with incorrect positioning on the belt. Packages with irregular flaps also need to be removed from the production line. If you have fast-paced operations, you need to have a checkweigher that is responsive and monitors the operations at all times.

17.17 Additional weight zones If you have a large-scale operation process, you need to have a minimum of three standard weight zones. This is in addition to their product counters.It is advisable to have an extension that can support four additional zones. You can then assign individual action to each zone.

17.18 Data security Based on the country you operate in, you might need to have data protection of production lines, record maintenance, and monitoring of access to all equipment. The security needs to be top-notch for the manufacturing processes. You need to have only your authorized personnel access sensitive information like records.

17.19 Traceability If you have a sensitive manufacturing process, you need to have the function to trace the various steps in the production process. You need easy solutions that are also safe at the same time. You can get traceability with the help of documentation systems. You can store all the production data on a central PC for centralized data analysis.

17.20 Data handling flexibility You will often need the production data for processing at different places like generating stats or reports. You can get the encrypted data in USB storage for seamless access and handling of data. The data stored in USB storage can also help you when there are system failures.

17.21 Secondary functions The expectations from checkweigher will be varied based on the factors like the product characteristics,production situation, statutory requirements, business goals, etc. These help in ensuring an efficient production process. So you need to find a checkweigher manufacturer that understands your secondary requirements and proposes solutions accordingly.

17.22 Statistics functions Many checkweighers allow storage and display of statistical analyses. You can get data records and printouts with the help of a reliable checkweigher. You can have a fixed schedule like after weighing a certain number of products, changing the parameter settings, or individual requests. You need to opt for a checkweigher manufacturer that gives you the option of the latest statistical software based on your regulatory and business requirements.

17.23 Program details There are several functions in a checkweigher, which can affect the manufacturing process. As part of the quality control measures, you will often have to withdraw samples without production or take measurements after regular intervals. So you will need customized solutions. An automatic display of the measured weight or piece count can make the process easy. You will need the production process to have the highest optimization.

18. Checkweigher feedback system

A checkweigher’s feedback control system helps in reducing product giveaway and product weight errors. This becomes possible with through timely feedback, which also helps in filler heads adjustment. If you want to have a flawless feedback control, you can integrate the checkweigher with the filler control. Additionally, you can also network it to the present factory floor automation systems.

The filler feedback system works on the calculation of a mean weight value of fixed weighings during a fixed period. Any deviation between the mean value and the target weight sends a control signal to the filler for adjusting the fill levels. So it is an ongoing process that ensures accuracy of the system.

The feedback system is beneficial for checkweigher operators in a number of ways like: • Optimizes the filling process • Reduces over or under filling • Avoids product giveaway • Reduces rejects and scrapping of products • Ensures compliance with regulatory norms • Meets consistent product quality

19. Data management on cloud and its analysis

Many checkweighers come with advanced software that aid in centralized monitoring of the equipment and data access. This is possible even when you have checkweighers at multiple locations. When you make it a part of your product monitoring program, it can not only add to the operational security but also improve the productivity of the process.

Technologies like IoT and Big Data enable the transportation of checkweigher data in the cloud for further analysis. Without the absence of this technology, you will have to rely on human efforts for record tracking. This can often lead to human errors and reduce work efficiency. When the data remains stored on the cloud, it facilitates better data analysis and management.

20. Checkweigher Market Trends

Here are some checkweigher trends that you need to watch out for.

20.1 Strain gauge technology-based automatic checkweighers will become popular This is the most common technology adopted by automatic checkweighers. The load gets converted into electrical signals with the help of the strain gauge. It becomes possible to get an accurate real-time extent of the load when the output of the voltage signal gets attached to a scale. The strain gauge technology-based automatic checkweighers have proven proficiency, accuracy, and lifespan.

The strain gauge load cell technology also fits well with the automatic checkweighers because of its design and small size. Furthermore, regulatory bodies and the demand from consumers have led to the technology becoming popular.

20.2 EMFR technology-based automatic checkweighers will grow better in global market As the demands for sustained accuracy and performance are on the rise, EMFR technology will become popular. It offers quick settling times, reduced product gaps, and precision in weighing accuracy with excellent throughput speeds. It is thus very likely that the EMFR technology-based automatic checkweighers will be in a lot of demand in the coming years.

20.3 Pharma industry will register the highest demand for automatic checkweighers The pharmaceuticals industry is growing rapidly, especially after the Covid-19 pandemic. Pharma companies today need automatic solutions for weighing capsules, pouches, , bags, cans, , etc. They also need to meet the regulatory norms and prevent fines, which leads to an increased demand for automatic checkweighers.

20.4 APAC will be the fastest-growing market for checkweighers As the packaging industry is experiencing a boom, there is also increased consumer awareness regarding labeling and packaging of finished products. This also leads to an increased demand for automation. All these factors will push the need for automatic checkweighers in the Asia-Pacific (APAC) region. Countries like India, Japan, China, South Korea, and Australia will continue to have the most demand for automatic checkweighers.

21. Future of checkweigher

The global automatic checkweigher market was valued at USD 238 million in 2019. The same is expected to grow to USD 289 million by 2024, at a compound annual growth rate (CAGR) of 4%. There are several factors that are causing a spurt in the demand for automatic checkweighers. Some of these include the rise of food & beverages, and consumer products industries. These are high-growth segments and business owners know the importance of having automated equipments for meeting regulatory norms and delivering quality products.

References 1. https://www.packagingdigest.com/inspection/how-checkweighers-help-ensure- quality-packaging 2. https://www.legislation.gov.uk/uksi/2006/659/pdfs/uksi_20060659_en.pdf 3. https://www.nist.gov/customcf/get_pdf.cfm?pub_id=912434 4. https://mspace.lib.umanitoba.ca/bitstream/handle/1993/7879/10- Final%20Report.pdf?sequence=1 5. https://www.packagingstrategies.com/ext/resources/FDP/Home/Files/PDF/Principl esofCheckweighing.pdf 6. https://www.directindustry.com/industrial-manufacturer/checkweigher-65280.html 7. https://www.americanpharmaceuticalreview.com/25310-Pharmaceutical- Manufacturing/25273-Pharmaceutical-Checkweighers-Checkweigher-Conveyor- Capsule-Checkweigher/ 8. https://www.marketsandmarkets.com/Market-Reports/automatic-checkweigher- market-188613743.html 9. https://ieeexplore.ieee.org/abstract/document/9186200 10. https://www.epmmagazine.com/opinion/the-importance-of-weight-in- pharmaceutical-packaging/ 11. https://www.pharmaceuticalonline.com/doc/pharmaceutical-checkweighers-kke- 25003800-0001 12. https://www.dairyfoods.com/keywords/checkweighers 13. http://www.foreviewengg.com/check-weigher-machine.html 14. https://www.marketsandmarkets.com/Market-Reports/automatic-checkweigher- market-188613743.html 15. https://www.mt.com/dam/product_organizations/pi/whitepapers/Optimisation- Solutions/Production-Process-Optimisation-Solutions-EN.pdf 16. https://www.mt.com/in/en/home/library/applications/industrial- scales/download/dc_data_collection.html 17. https://www.mt.com/dam/product_organizations/pi/Product-Inspect- Campaigns/Applications/Filll- Levels/App_04_feedback_control_function_as_overfilling_does_not_pay-EN.pdf