News7Bakery, Snacks

& SweetsIndustrial Weighing and Measuring

overa6monthperiod.DuringPhaseIoftheproject,thecustomerinstalledasinglestationconsistingofoneID30–anindus-trial PC weighing terminal and a KA15sweighingplatform(15kg×0.1g)–astain-lesssteel,high-precisionscalebasecapableof withstanding wet wash-down environ-ments. FreeWeigh.Net® the METTLERTOLEDO Statistical Quality Control soft-warewas installed so the customer couldtrackthefillingprocess.

Immediate adjustmentsFreeWeigh.Net® records and tracks netweightandotherqualitydatafromsam-ples takenoff theproduction line.Fromthesampledata itcalculatesproductionmean, range and standard deviation,whichisthebasisforqualityassessment.Foroperatorsandsupervisorsthisdatais

Fill weights were inconsistent and fill-er operators were not performing theStatistical Quality Control (SQC) processcorrectly.The customerneededamethodby which they could monitor fill weightsandattributessuchasproductappearance,labeling,andexpirationdateonareal-timebasis enabling immediateadjustments tobemadetotheirprocesseswhenrequired.

METTLER TOLEDO fills in the gaps Afterhearingaboutthecustomer’sproblem,METTLERTOLEDOperformedasite-studytofindoutexactlywhereinefficiencieswereoccurring.Anequipmentspecificationandrecommendationwasdeliveredtothecus-tomershortlyafterthevisit.BothMETTLERTOLEDOandthecustomerdeterminedthattheprojectcouldbedeliveredintwophases

Complete Quality Control SystemA Solution for Filling for the Food Industry

Filling containers requires very fast, precise and repeatable results. Inconsistency in

weighing can be costly – either giving away product by overfilling containers or risking

fines by not meeting Weights and Measures standards or net weight legislations.

A large US pudding and yogurt manufacturer was facing this exact problem monitoring

their fill weights during packaging.

2 METTLER TOLEDO Bakery, Snacks & Sweets News 6

Publisher Mettler-Toledo AG Industrial Heuwinkelstrasse CH-8606 Nänikon Switzerland Production MarCom Industrial CH-8606 Nänikon Switzerland Subject to technical changes © 07/2008 Mettler-Toledo AG Printed in Switzerland

Stat

istic

al Q

ualit

y Co

ntro

l madeavailableonlineon thePC-termi-nals.Thisdata iscrucial for immediateadjustmentdecisionsandismadeavail-able to operators and supervisors on aPC-terminalat theproduction line.Theresult is much tighter control over theprocessanddrasticreductioninoverfill.Configurablereportsaregeneratedauto-

matically by FreeWeigh.Net® being thequality documentation of the producedbatches – without requiring additionaleffortbythecompany’spersonnel.

The system completely paid backThecustomernoticedanimmediatediffer-enceininventory–andaftersixmonthsthe Phase I system completely paid foritselfbyreducingoverfillcosts.Basedonthesuccessofthefirstphase,thecustomercompletedPhaseIIoftheprojectbyinstall-ingadditionalequipmentintotheirfacil-ity.Thefinal system includes four ID30workstations with KA15s weighing plat-formsandFreeWeigh.Net®softwarewhichallowsthemanagertomonitorthefillingprocess froma remotePC. AnattributesmodulewasaddedtotheFreeWeigh.Net®installation to trackotherquality char-acteristics such as product appearance,labeling,andexpirationdateinadditiontonetweight.AfterPhaseIIthecompanynowhasa completequality control sys-tem. The package was secured with aMETTLER TOLEDO service agreementwhich includes regular calibrationsandstandardmaintenance checks to ensurethat the equipment continues to delivergreatresults.

Fast facts: KA15s weighing platform

• Capacity: 15 kg• Resolution: 1g

Weights & Measures approved• Platform size:

280 × 350 mm• Full stainless steel• Load plate: AISI304,

optionally AISI316• IP67 protected

Key customer benefits of FreeWeigh.Net®:• Significant reduction of product

overfill 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)

Attributes and testplans module:

Input of product quality attributes from visual inspection and execution of Test-plans-linking individual measurements and checks together to a sequence.

• Ensures completeness of quality data• Simple operation• Graphical representation

Master stationSupervisor’s office

Ethe

rnet

Graphical representations and analysis of net content and other quality data

Configurable quality docmentation

Production Line 1

Production Line 1

Production Line 1

Production Line 1

3METTLER TOLEDO Bakery, Snacks & Sweets News 6

Theterminalwithitslargedisplayisfastandeasytooperate.Thescaleoffersover/undercheckweighing,portioning,classi-fyingandcountingfunctions.ItfeaturesaRS232interfacetocoveryourdatacom-municationneeds.Furthermore,itispow-eredeitherby4-Csizebatteriesoroption-allybyarechargeablebatterypack,whichenablesthescaletobeusedflexiblyacrossthewholepremises.Choosefromawiderangeofaccessories:rollertrack,ballplatter,standorwallfix-

The BBA221 is a scale for your routine applications in dry areas,

such as your receiving department or warehouse.

turefortheterminal.The500×650mmand600×800mmsizeweighbridgescanalso bemounted ona cart andused asmobilescales.

Easy to operateFor manual portioning or checkweigh-ing applications the BBA221 featuresa straightforward and easy to handlethreshold definition system. Activate theapplication by F functionkey, store thetargetweightaswellasthepredefinedtol-erancesandyouarereadytogo.Automatic taring allows operationwith-outpushingthetarebutton.Afterplacingtheemptycontainerontheweighingplat-form,theweightisautomaticallysavedasthe tareweight (net indicator appears),thisallowsfastandtime-savingoperationandalsoresultsinlessfailure.

The weight valueFor higher precision measurements theterminalfeaturesa×10function,whichdisplaysthereceivedvaluewithahigherresolution(×10)forapproximative20sec-onds(notWeights&Measuresapproved).

Ball platter Roller track

Stands: carbon orstainless steel(300, 600, 900mm)

Key benefits and facts BBA221

• Easy to perform accurate checkweighing, portioning and classifying measurements

• Weighing range 6 to 300 kg or 13.5–660 lb

• Max. Resolution: 30 000d, OIML 3000e NTEP 5000d

• Fast indication of the weighing result on the big LED display (< 1 s)

• High mobility due to integrated 4-C size batteries or optionally a rechargeable battery pack and cart

• Standard RS232 Interface• Rugged, painted carbon steel plat- form with 6 integrated overload stops• Optional: Stainless steel terminal

(IND226), internal rechargeable battery pack, cart, roller track, ball platter

×10 Function for higher resolution

Mobile weighing: IND221 with cart

Over, ok, under indication for checkweighing, portioning

and classifying applications

BBA221 bench scaleFunctional design allowing easy, intuitive operation

Printing/transferring data

Function key

Unit switch indication

Bench and Mobile Weighing For Your Routine Applications in Dry Areas

4 METTLER TOLEDO Bakery, Snacks & Sweets News 6

Sani

tary

Equ

ipm

ent D

esig

n Sanitary Equipment DesignFor Your Brand’s Reputation

Safety and integrity of your products is at the very heart of your brand’s reputation.

When sanitation practices are insufficient, bacteria can harbor and thrive in equip-

ment used in food processing. Also scales may harbor and transfer the bacteria to products.

When this occurs, scrupulous sanitation must occur to eliminate potential hazards.

Bothindustryandgovernmentarework-ing diligently to reduce the incidence ofbacteria’s such as Listeria in foods andpreventitsgrowthandspreadinfoodpro-cessing plants. Equipment is a potentialsourceofpathogengrowth–so is it thescale!Oneofthemostimportantfactorstoconsiderwhenbuyingscalesfortheuseinfoodprocessingaredesignandconstruc-tionasrelatedtocleanabilityandthetypeofmaterialusedforconstruction.

Guidelines to evaluate cleanabilityThe American Meat Institute has es-tablished an Equipment Design TaskForce with the objective to minimizethe spread of Listeria in meat process-ing plants. This Task Force has es-tablished sanitary design principlesand criteria in consultation with equip-

mentmanufacturers, certifyingorgani-zations and government officials. Thefollowing10principlesofsanitarydesignhavebeendeveloped.

1. Cleanabletoamicrobiologicallevel:Food equipmentmust be constructed toensureeffectiveandefficientcleaningoverthelifeoftheequipment.Theequipmentshouldbedesignedastopreventbacterialingress,survival,growthandreproductiononbothproductandnon-productcontactsurfacesoftheequipment.

2. Madeofcompatiblematerials:Con-struction materials used for equipmentmust be completely compatiblewith theproduct,environment,cleaningandsani-tizingchemicalsandthemethodsofclean-ingandsanitation.

3. Accessible for inspection, mainte-nance,cleaningandsanitation:Allpartsoftheequipmentshallbereadilyaccessi-bleforinspection,maintenance,cleaningandsanitationwithouttheuseoftools.

4. Noproductorliquidcollection:Equip-mentshouldbeself-drainingtoassurethatliquid,whichcanharborandpromotethegrowthofbacteria,doesnotaccumulate,poolorcondenseontheequipment.

5. Hollowareas of equipment suchasframes and rollers must be eliminatedwhereverpossibleorpermanentlysealed.Bolts, studs, mounting plates, brackets,junction boxes, nameplates, end caps,sleevesandothersuchitemsmustbecon-tinuously welded to the surface not at-tachedviadrilledandtappedholes.

6. Noniches: Equipment parts shouldbefreeofnichessuchaspits,cracks,cor-rosion, recesses, open seams, gaps, lapseams,protrudingledges,insidethreads,boltrivetsanddeadends.

Your benefits

• Reduce biological and chemical contamination risks• Fast and thorough cleaning procedures• Fulfillment of hygiene regulations• Long equipment life due to rugged design

Open, easy-to-clean construction with no hidden holes

Hermetically sealed loadcells,IP68 for prolonged submersion andIP69k for high pressure washdown

Minimal horizontal surfaces avoiding remaining water (bacteria)

PBA430 bench scale

5METTLER TOLEDO Bakery, Snacks & Sweets News 6

7. Sanitary operational performance:Duringnormaloperations,theequipmentmustperformsoitdoesnotcontributetounsanitary conditions or the harborageandgrowthofbacteria.

8. Hygienic design of maintenanceenclosures:Maintenance enclosures andhumanmachineinterfacessuchaspushbuttons, valve handles, switches andtouchscreens,mustbedesigned,toensurefoodproduct,waterorproductliquiddoesnotpenetrateoraccumulateinandontheenclosureor interface.Also,physicalde-signoftheenclosuresshouldbeslopedorpitchedtoavoiduseasstoragearea.

9. Hygienic compatibility with otherplant systems: Equipment design mustensurehygienic compatibilitywith otherequipmentandsystems,suchaselectrical,hydraulics,steam,airandwater.

10. Validatedcleaningandsanitizingpro-tocols:Proceduresforcleaningandsanita-tionmustbeclearlywritten,designedandproven effective and efficient. Chemicalsrecommendedforcleaningandsanitationmust be compatiblewith the equipmentandthemanufacturingenvironment.

Source: AMI Fact Sheet: Sanitary Equipment Design, Amercian Meat Institute, March 2007

Sanitary scales METTLER TOLEDOhas seriously takentheseguidelinesintoaccount.Construct-edafterthelatesthygienicdesignguide-linesofNSFandEHEDG,ourscaleswith-standharshestcleaningproceduressuchassubmersion(IP68)andhighpressurecleaning(IP69k).Profitfromhygienicallydesignedscalesallowingthoroughlyandefficientcleaning!

www.mt.com/ind-hygienic-design

Simple Weighing

Filling/Dosing

Batching/Blending

Fomulation/Recipe

Inventory Management

Inbound/Outbound Vehicle Weighing

SQC/SPC/Quality Assurance

Counting

Over/Under Checkweighing

In-Line Checkweighing

Mobile Weighing

Customer Specific

NSF: National Sanitation Foundation

American non-profit and non-governmental organization. It is the wold’s leading organization in – standards development, – product certification, – education, and – risk-management for public health and safety.

EHEDG: European Hygienic Engineering and Design Group

Consortium of – food manufacturers, – equipment manufacturers, – research institutes and – public health authorities, with the aim to promote hygiene during processing and packaging of food products.

Sanitary scales and terminals:

IP68 IP69k EHEDG NSF GMP Applications

Floor scale PUA579 • • •Bench scale PBA430 • • • • •Combi scale BBA4x9 • • • •Terminal IND4x9 • • • •Terminal IND690 • • • •Terminal IND780 •PC terminal ID30 • •

Water ingress pro-tection up to IP69k

Closed, easy-to-clean back of the stand,no visible cable

Smooth surface (RA < 0.8 μm) for trouble-free cleaning

No open threads

No product can remain

Full AISI 304 stainless steel constructions, optional AISI 316 load plates

BBA4x9 combi scale

Protected against submersion

Dustproof and suitablefor cleaning with high-pressure equipment

6 METTLER TOLEDO Bakery, Snacks & Sweets News 6

MTX

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Vehi

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Scal

es Reliable Vehicle Weighing with MTX Load Cells

With more than 600 000 in service worldwide, POWERCELL® MTX®

load cells have a proven history of accurate and reliable

performance in the toughest environments.

The MTX load cell uses provenPOWERCELL technology thatprovides theultimate in weighing for trucks and railcars.Inadditiontoweighingaccuratelyinalltypesofclimates,itoperatesreliablyoveralongservicelife.Theresultisaheavy-ca-pacityloadcellthatdeliversthebestvaluefor yourmoneybymeeting the real-worlddemandsofvehicleweighing.

ReliabilityEveryminutethatascaleisnotabletoop-eratemeans lost revenue.MTX loadcellsaredesignedtokeepyourscalerunningbypreventingproblemsandbyhelpingtosolvethemiftheydooccur:

• SolidConstruction–Thedurablestain-lesssteelloadcellperformsinthetough-estenvironments.Itishermeticallysealedtoprotecttheinternalelectroniccompo-nents fromdamage inwetor corrosiveconditions.Thewater-tight enclosure isratedIP68/69ktowithstandcontinuousimmersionandpowerwashing.

• DebrisProtection–Apliablebootkeepsdust anddebris fromcollectingaroundthe load pin. That allows the load pintomove freely,helping tomaintain thescale’sweighingaccuracy.

• LightningProtection–Theloadcellhasbuilt-in transient voltage suppressors

thatprotectagainst costlydamageduetolightningstrikesandpowersurges.Itisakeypartofourfour-stagelightningprotection system, which also includesdouble-shielded cables, current-block-ing junction boxes, and a single-pointgroundingkit.Thesystemwastestedbyanindependentlaboratorytosimulatea10000-amplightningstrike.

• Self-Diagnostics–Each load cell calcu-latesandtransmitsaweight15timespersecond. If there is aweighingerror, theload cell notifies the scale operator in-stantly,allowingmaintenancepersonnel

topinpointtheproblemandgetthescalebackinservicequickly.

Exceptional valueWhenselectingaloadcell,consideritstotalcost of ownership. Inaddition to the initialpurchaseprice,factorinthecostofdowntime,maintenance,service,andlostinventory.Anyinitialsavingsfrombuyingeconomyloadcellsareeatenupbytheincreasedcostofupkeep.Byprovidingthemostreliableheavy-capacityweighingintheindustry,MTXloadcellsgiveyouthebestvalueoverthelifeofyourscale.

www.mt.com/vehicle

POWERCELL® MTX® Load Cell

17-4 PH precipitation-hardened stainless steel receiver

hermetically sealed enclosure

Debris-protection boot

Built-in lightning protection and self diagnostic capabilities

Corrosion-resistant polished 304 stainless steel

17-4 PH stainless steel load pin

7METTLER TOLEDO Bakery, Snacks & Sweets News 6

Kuchenmeister Ensures High Quality Standardswith Product Inspection Equipment

To achieve optimal production processes and a consistent, high quality product, Kuchenmeister

uses a range of product inspection equipment from METTLER TOLEDO, including dynamic

checkweighers and Safeline metal detection and X-ray inspection systems.

Kuchenmeister, a family-owned bakery,hasbeenproducingarangeofbakeryspe-cialitiesforover120years.ThecompanyaremarketleadersincakesandareoneofthelargestbakeriesinGermany,distribut-ingover500productsworldwide,undertheirownandretailerbrandnames.

“Toensurethehighqualityofourprod-uctswehavetoworkinstrictaccordancewithourrecipes,”explainsDr.Zurhelle,Head of Quality Assurance. “We havehigh standards regarding the qualityandtasteofourproducts.”Thecomputercontrolledproductionequipmentincom-bination with the latest machines andstate-of-the-art technology ensureopti-misedproductprocessesandconsistent,highqualityproducts.

METTLERTOLEDOinstalledaCombiCheckerto ensure thequality of theirMilkyWaycroissants. This machine combines acheckweigher and a metal detector, en-suring products are not only producedto the requiredweight but are free frommetalcontamination.210productscanbeweighedperminuteatanaccuracyofupto300mg.Productsthatdonotmeetthesestandards are automatically rejected, inaccordancewithstrictIFSandWeightsandMeasuresqualitycriteria.

Kuchenmeister’s foil wrapped cakes areinspected using METTLER TOLEDOSafeline’s X-ray machines which detectand reject products with contamina-tion, missing content or those incor-rectlysealed.Despitethemetallizedfilm

packaging,theX-raysystemcandetectarangeof contaminantsoftenoriginatingfrom the farmers field, gathered inwiththerawingredients.

Through METTLER TOLEDO servicesupport which offers competent advice,on-site operator training and verifica-tion packages, Kuchenmeister can beconfident they can rely on METTLERTOLEDO to ensure optimum productionprocesses, high uptime and consistenthighqualityproducts.

A CombiChecker was installed in addition to the checkweigher

SAFELINE X-ray machine inspecting foil wrapped cakes

For more informationwww.mt.com/ind-bakery-snacks-sweets

Your METTLER TOLEDO contact:

USAMettler-Toledo, Inc.1900 Polaris ParkwayColumbus, OH, 43240Tel. (1) 800 523 5123

CanadaMettler-Toledo, Inc. 2915 Argentia Road, Unit 6Mississauga, Ontario, L5N 8G6Tel. (1) 905 821 4200

Mettler-Toledo AGSales InternationalCH-8606 GreifenseeSwitzerlandTel. + 41 44 944 22 11

News7Bakery, Snacks

& SweetsIndustrial Weighing and Measuring

Brochures/Catalogs:1.StatisticalQualityControl/StatisticalProcessControlBrochure2.FoodandBeveragesBrochure3.IndustrialWeighingCatalog

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disposal in print or online.

Learnmoreaboutallofoursolutionsforthe bakery, snacks and sweets industryatourwebsite.Youcanfindinformationonawiderangeoftopicstoimproveyour

processes,includingcasestudies,applica-tionstories,return-oninvestmentcalcula-tors,plusalltheproductinformationyouneedtomakeaninformeddecision.

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