chocolate & 2 confectionery news - mettler toledo · confectionery the plant in lebbeke-wieze...

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Industrial weighing and measuring

Chocolate & Confectionery

The plant in Lebbeke-Wieze producesanannualoutputofmorethan250000tonnes. At the very beginning of thechocolate manufacturing procedure,duringcocoaprocessing,productionisfocusedonmixing,batchingandfillingoperationswithahighthroughputandhighdegreeofautomation.AtthisstageMETTLERTOLEDO is a reliable partnerforfastandaccuratemeasurements.

Raw material batching and chocolate mass temperingBatchingtheexactamountofrawmaterialsisakeyfactorwhenproducinghighqual-itychocolate.UponrecommendationfromMETTLERTOLEDOBelgium,BarryCalle-bautchoseFlexMount®weighmodulesandPTPNprocessterminalstoweighbatchingandtemperingtanksaswellasmixingsta-

tions.Thesolutionassuresfastandpreciseweighingofcriticalcomponentspluseasydataintegration,whicharebothvitalforanefficientproductionprocess.

Easy data integrationWeighing results are transmitted fromPTPNprocess terminalswithProfibus®DP directly intoBarryCallebaut’s auto-mationsystem.ThePTPNterminalsen-suretrouble-freeconnectivitywith20up-datespersecond.

Barry Callebaut’s benefitsDue to the simple but very effectivemounting accessories and the plugandplayconnection,theMETTLERTOLEDOweighmodulesand terminalswere easytoinstall.Incontrarytootherlevelsen-sors, loadcellsarenotaffectedbydust,

Barry Callebaut Weighs with Fast and Precise Measuring Technology

Barry Callebaut is the world’s leading manufacturer of high-quality

cocoa, chocolate and confectionery products. In the factory in

Lebbeke-Wieze (Belgium) the transfer of raw materials is controlled

by METTLER TOLEDO weigh modules, platforms and indicators.

METTLER TOLEDO Chocolate & Confectionery News 22

PublisherMettler-Toledo AGIndustrialHeuwinkelstrasseCH-8606 NänikonSwitzerland

ProductionMarCom IndustrialCH-8606 NänikonSwitzerland

MTSI 44099130

Subject to technical changes© 06/2007 Mettler-Toledo AGPrinted in Switzerland

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l foamand solidswhichdonotdistributeevenlyintanks.Thisensuresaccurateandrepeatablemeasurementofmasswithoutdirectmediacontact.

BartGoetmaeckers,EngineeringManager,explains why he has chosen METTLERTOLEDO weighing equipment: “Due totheinstalledsolution,wehaveachievedafasterbatchingprocessandincreasedpre-cisionandconsistencyinmaterialtrans-fer.Thehighqualityoftheweighmodulesresultsinminimalmaintenancecostsandmaximum uptime, thus improving ourproductivity.”

Key customer benefits:

PTPN Process terminal• Standardization through the whole factory• Easy-to-integrate• Fast, reliable weight measurement and data transfer to automation system• Easy integration with Profibus® DP• Faster batching process through su-

preme TraxDSP™ noise and vibration filtering

FlexMount® Weigh module• Reliable and proven measuring technique• Easy-to-integrate• Easy to service• Rugged and full stainless steel

construction

Tempering tanks on FlexMount® weigh modules

Raw material batching with PTPN process terminals

The floating, semi-floating or fixed top plate design provides system checking while al-lowing the structure to expand and contract.

The hermetically sealed load cell offers excel-lent performance and durability.

The stainless steel load pin makes point con-tact with the load cell for optimum accuracy.

The anti-lift/jacking bolt prevents vessels from tipping over, and provides a convenient method of lifting empty vessels for mainte-nance and service activities.

TraxDSP™ is a patented filter design that practically eliminates environmental noise and vibration to provide stable weights.

METTLER TOLEDO Chocolate & Confectionery News 2 3

BartGoetmaeckersconcludes:“WeareverysatisfiedwiththequalityoftheequipmentandtheservicecapabilitiesofMETTLERTOLEDO.Theysupportuswith theirex-pertise inweighing technology and tai-lored service, helpingus to ensurehighuptime,qualityandcompliance.”

5kg chocolate bars: net content control with METTLER TOLEDO platform integrated into the conveyor (see picture below)

25kg chocolate pellets bags: 100% net content control by dynamicMETTLER TOLEDO Garvens checkweigher

Net content control for chocolate bars, pellets and creamControllingfillingorpackageweightspaysoffintwoways.Firstthereisfullcompli-ancewithnationalandinternationalnetcontent legislation regarding under fill-ing and secondly it assures minimumgiveaway.At themoldingstationfor5kgchocolatebars,thechocolatecreamfill-ingstationandthepelletpackagingline,METTLER TOLEDO weighing solutionscontrolthefillinglevelandcontributetocostreductions.

Fast facts FlexMount® weigh module:

Hermetically sealed stainless steel IP68 load cell – the right choice for hygienic sensitive areas

• Capacity range 110kg – 20.4t• Top plate rigidly located for easy installation• Uplift protection• Large range of thermal expansion/contraction possible• Painted or stainless steel mounting hardware• Global approvals standard on every load cell

Over 80 Tank Scales Reliably Running Day in Day out

Dustproof and protected against submersion


Reci

pe W

eigh

ing Enhance Traceability of Raw Materials

Used During Recipe Weighing

Do you want to minimize handling errors due to manual computation of recipes? Do you want to increase

productivity and improve traceability with an intelligent and PC based recipe weighing system?

Ifacomponenthasbeenoverfilledares-caling function is used which correctsothercorrespondingcomponents.

Manage all recipe relevant information with unique ID #•Rawmaterialsdatabase•Recipedatabase•Handlingandinstructiondatabase•UserID

Fromrecordingrawmaterialstoprocess-ingrecipes–FormXPguidestheusereas-ily and clearly.Due tonumerous inter-connecteddatabases,thedisplaycanalsoshow information suchaswork instruc-tions,quantitiesandtoleranceswhiletherecipeisbeingweighed.

ThenFormXP formulation softwarehitsthespot!FormXPmakesyourformulationprocesseasier,fail-proofandefficient.Se-lectoneoftheavailablefillingsequences,easilycreate,manageandexchangerecipeandrawmaterialdata,and trackmate-rial usage with the embedded inventorycontroltool.

Select your filling sequence•Vertical filling: All components of a

recipearefilledinonecontainer.• Horizontalfilling:Eachcomponentofa

recipeisfilledinaseparatecontainer.• Batchfilling:Eachcomponentofarecipe

isfilledinaseparatecontainer.Thecom-poundisfilledasoftenasassignedinthenumberofbatches.If thecompoundisbatched,thenextcompoundfollows.

Vertical recipe weighing

Weighing all components into a single container

Horizontal recipe weighing

Weighing each component into a separate container

Process recipe

Select recipe type

Messages

Select raw material

Batch recipe weighing

Multiple weighings of separate components into individual containers

Edit recipe dataFormXP includes FormToolXP, a specialPC software which enables you to editmessage, component and recipe data. Amouseclick on yourPCgives youdirectaccesstotheIND690ortoahostsystem.

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31 2 31 2

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IND690FormXP display


IND690 weighing indicator

FormXP is a software pac that runs on any IND690 weighing indicator. The additional FormToolXP PC software allows you to handle smoothly any task from your PC.

Document and trace backFormXPprintsreportswithcustomer-spe-cificdata–providing themanufacturerwithseamlessdocumentationofwhatrec-ipewasweighedwhen,where, howandwithwhichrawmaterials.

Key customer benefits •Enhancedtraceabilityofrecipesbyas-

signinglotandrawmaterialsnumbers•Accurateandreproduciblerecipes•Minimal waste material due to bad

batches• Easierhandlingandreducedpaperwork

resultsinhigherproductivity• Increased safety by capturing compo-

nent data via a barcode scanner, dis-playingmessageswhileformulatingandensuringafail-proofworkingsequence

•Higherefficiencybyreportingthestockofrawmaterialandusingtherescalingfunctionwhenoverfillingcomponents

•Quickeradaptiontochangingproduc-tionrequirementsbyusingthePC-soft-wareFormToolXP

Barcode scanner

Label printer

Up to 4 bench or floor scales connectable

IND690FormXP weighing indicator FormToolXP PC Software

Customized reports

FormToolXP: Recipes and raw materials


Keeping Control Over Production Costs Despite Rising Raw Material Prices

As a result of open globalized markets, food manufacturers have to operate under

constant price and cost pressures. They are forced to offer high-quality products at

competitive prices in order to survive in the face of critical consumers and aggressive

competition. This is made all the more difficult by the upwards trend in raw material

prices, which poses a serious threat to the profit margin. A comprehensive METTLER

TOLEDO quality and production control system, which is fully integrated in the produc-

tion process, helps to monitor and optimize these costs without having to compromise

on product quality.

Cont

rol O

ver P

rodu

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sts

Increasing raw material costsAglanceatthecurrenttrendsinrawma-terialpricesandstatementsfrommarketexperts paint a clear picture. Prices areunstable and future price developmentsareunpredictable.

Whilethepricetrendsforcoffeeandsugararecurrentlyonthedownturn,furtherin-creasescanbeexpectedinthenearfutureforotherrawmaterials.Forexample,thepriceofcocoaiscurrentlysoaring,asarethepricesofrapeseed,soya,andwheat.Theincreaseduseofcornandsoyaasrawma-terialsforenvironmentallyfriendlymotorfuelsmeansthatthesecerealswillcontinuetobecomemoreexpensiveinthefuture.

Withafewexceptions,itcanbeassumedthatmanufacturerswillhavetocontendwithhigher costswhenpurchasing rawmaterialsforfoodproduction.

Avoiding material wastageOne strategy that offers promising andworthwhile results in the short to me-diumtermistheuseofsuitabletoolsto

preciselymonitortheuseofrawmaterials,andtomaintaincontrolovertheirusetooptimizeconsumptionwithouthavingtocompromiseonproductquality.

METTLER TOLEDO offers sophisticatedsystemsintheareasofbothformulationandfillingprocesscontrol,whichenablestooptimizetheutilizationofrawmateri-als and endproducts through increasedaccuracyinallprocesssteps.

Efficient formulationFormWeigh.Net® is a flexible and net-workedformulationsolutionthatcontrolsandmonitorstheformulationprocess,en-ablingmaximumprecisionandflexibilityintheuseoftheavailablerawmaterials.This therefore guarantees transparentmanagement of the available materials,cleartraceability,andconsistentproductquality. The consumer can rest assuredthat the product he is buying does notcontain anyhidden surprises,while theproducercanbesurethatnotasingledropisunnecessarilywastedduringthemanu-facturingprocess.

Key customer benefits of FormWeigh.Net®:

• Right mixture reliably documented• Graphical support to avoid incorrect

mixtures• Prevention of material wastage• Acquisition and verification of batch

information• Clear, concise representation of the

weighing process• Maximum process reliability• Seamless traceability• ERP integration• Fast ROI (<12 months)


Example: Food industry – overfilling cost before and after FreeWeigh.Net® system introduction

105.00

104.00

103.00

102.00

101.00

100.00

40’000

32’000

24’000

16’000

8000

0

Overfill [US $]Overfill [%]

April

200

5

May

200

5

JUne

200

5

July

200

5

Aug.

200

5

Sept

. 200

5

Oct

. 200

5

Nov

. 200

5

Dec

. 200

5

Jan.

200

6

Feb.

200

6

Mar

ch 2

006

April

200

6

May

200

6

June

200

6

FreeWeigh.Net®

System introduction

6’4667’237

30’392

15’849

25’777

19’385

9’996

21’754

9’281

3’854 3’732 5’028

7’6688’846

32’456

Reduction of overfill costsAccuracyandtheminimizationofvariationarealsoofparamount importance in theareaoffillingandpackaging.Rawmateri-alsmustbeusedaseconomicallyaspossi-blewhileremainingwithinlegallimits.

METTLERTOLEDOSQC(StatisticalQual-ityControl)systemsactasextremelyvalu-able information sources since they canprovideinformationatanytimeaboutthecurrentfillquantitybasedontheevalu-ationofsampledatafromtheproductionline,andthereforehelptooptimizethefillquantitywhileavoidingunderfilling.

The METTLER TOLEDO SQC productrangeincludescompactstandalonescale-basedsolutionsaswellasthenetworkedand flexibly extendable FreeWeigh.Net®softwaresystem.FreeWeigh.Net®offers,inadditiontofillingprocesscontrol,avari-etyof furtheroptionsforqualitycontrol

area of formulation and filling processcontrolhelp foodmanufacturers toopti-mizecostsandhencetoremaincompeti-tiveandprofitable,despiteuncontrollablefactorssuchasthepriceofrawmaterials.

METTLER TOLEDO offers appropriateprocesscontrolsolutionsthatcanbeeas-ilyexpandedtosuitbusinessesofallsizes.The investment iseasily justifiedby im-provedprocesscontrol,andpaysforitself

Key customer benefits of FreeWeigh.Net®:

• Significant reduction of product over-fill cost

• Compliance to legal fill requirements• Standardized and simplified processes• Online monitoring and alarming• Short reaction time in production• Automated reporting• Scalable system implementation and

enhancement• ERP integration• Fast ROI (<12 months)

suchasdocumentingsensorytestsand/orintegratingmeasuringdeviceslikecheck-weighers,moisture analyzers andmetaldetectors.

Process control andoptimization in the

withinamatterofmonthsduetothesav-ingsthatcanbeachieved.

www.mt.com/formweighnet www.mt.com/freeweighnet

www.mt.com/ind-chocolateFor more information

Mettler-Toledo AGCH-8606 GreifenseeSwitzerlandTel. + 41 44 944 22 11Fax + 41 44 944 30 60

Your METTLER TOLEDO contact:

A Wide Range of Solutionsto Improve Processes1.Safeline®metaldetectors2.FP900Thermosystem(meltingpoint,...)3.BBA449over/undercheckscalewithcoloredbacklight4.Halogenmoistureanalyzer

1.ProcessWeighing2.IND690FormXPRecipeWeighingSolution3.StatisticalQualityControl/StatisticalProcessControl4.WeighingComponentsCatalog5.IndustrialWeighingCatalog

Share Our KnowledgeLearn from our specialists – our knowledge and experience are at your

disposal in print or online.

Learnmoreaboutallofoursolutionsforthechocolateandconfectioneryindustryonourwebsite.Youcanfindinformationonawiderangeoftopicstoimproveyour

processes, including case studies, appli-cationstories, return-on investmentcal-culators,plusalltheproductinformationyouneedtomakeaninformeddecision.

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