safety first beware of hidden hazards · sible hazards in a timely manner. the chemical industry...

5NewsIndustrial Weighing & Product Inspection

Chemicals

scrutinize workplace, equipment and pro-cesses for potential hazards to further im-prove the safety situation.

Weighing applications are part of many production steps – from material receiving and batching to quality control and ship-ping. A close examination of the possible risks found in weighing workplaces identi-fies three areas that need to be considered to improve workplace safety.

1. Equipment-handling risksThe material quality, design and construc-tion of weighing equipment can contribute to injuries. For example, sharp edges on the load plate or unprotected cabling can be hazardous.

Disasters, such as the 2013 explosion at West Fertilizer in the USA or the 2015 in-cident at Tianjin in China, created signif-icant attention because of their impact in terms of human lives and material dam-ages. However, a look at the total num-ber of work-related injuries shows that the majority are caused by hazards, such as slipping and tripping. Those everyday inci-dents accumulate to significant numbers of fatalities, injuries and costs.

Historically, the chemical industry has made significant progress improving oc-cupational health and safety (see chart on page 2). However, during the last decade, the development has stagnated. Conse-quently, businesses and regulatory bodies

Safety FirstBeware of Hidden Hazards

Weighing processes can present safety risks that should be identified and

properly analyzed so you may take appropriate counter measures. Our experts

share which considerations are the most important for immediate safety im-

provements within your processes.

32 METTLER TOLEDO Chemicals News 5 METTLER TOLEDO Chemicals News 5

Wor

kpla

ce S

afet

y In the case of dynamic checkweighers, pinch-points created by moving compo-nents, such as conveyors and automatic reject devices, can pose a safety risk.

Floor scales can present slipping and trip-ping risks or, if equipped with insufficient lifting mechanisms, may lead to serious injuries if the load plate collapses.

2. Process-safety risksIn some cases, insufficient weighing ac-curacy can pose a safety risk. For exam-ple, when a catalyst is dosed into a reac-tor by weight, even small deviations might cause an out-of-control reaction with se-

rious consequences for workplace safety. Those weight deviations can come from different sources, including weighing on a scale that does not provide the required ac-curacy for the process. Operator error, such as using the wrong scale, measuring inac-curately or even measuring the wrong ma-terial may also contribute. Such operating mistakes can be eliminated by using ad-vanced weighing systems that guide the operator through the process or that auto-mate the weighing process altogether.

3. Explosion risksMany weighing processes are located in potentially explosive environments. There,

it is essential to use only weighing equip-ment that is approved for the respective hazardous-area. Safe weighing applica-tions can be realized with equipment that is designed according to intrinsic-safety protection principles. Regular equipment inspections are mandatory to identify pos-sible hazards in a timely manner.

The chemical industry has worked hard to eliminate the major hazards which are in-herent to the business. To further improve workplace safety, companies need to ad-dress the hidden hazards. The good news is that weighing safety risks can often be eliminated with simple improvements to equipment and processes.

Publisher / ProductionMettler-Toledo AGIndustrial DivisionHeuwinkelstrasseCH-8606 NänikonSwitzerland

Subject to technical changes© 09/2016 Mettler-Toledo GmbH

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2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013The rate of lost work days of Responsible Care member companies remains stagnant after initial improvements. LWD is defined as the total number of lost days x 200,000 / number of employee hours worked. (Source: International Council of Chemical Associations)

Expert InterviewSafe Material Handling with Floor Scales

Gary, what are the biggest risks when handling floor scales?The most common accidents that hap-pen with floor scales involve slipping and tripping. Especially when liquid materi-als are weighed on the platforms, spill-ing can cause operators to slip and injure themselves.

“Special surface designprevents slipping.”

Floor scales often extend up to 20 centi-meters above ground, which can present a tripping risk. In addition, elevated floor scales require ramps to move the materi-als onto the weighing platform. That re-quires a lot of power from operators and can lead to accidents, such as materials falling over or pallet trucks running away. So, what can be done to reduce the risk of slipping and tripping?The slipping risk can be reduced by using load plates and ramps with a special sur-face design to ensure safe footing. Re-garding the tripping risk, there are two approaches to improve safety. Either the floor scale can be installed in a pit, which makes it level with the floor. Or, a low-pro-file floor scale can be used, which is much

easier and safer to operate than a stan-dard product. In either case, the floor scale should be located away from through-traf-fic to reduce the tripping risk.

“No more tripping with low-profile platforms.”

Are there specific risks related to liftable floor scales?Floor scales with lifting mechanisms pro-vide great benefits, such as easy servicing or fast and efficient cleaning procedures. But this type of floor scale also may pose a safety risk to the operator if the load plate is not held securely in place.

“Beware of insufficient lifting mechanisms.”

What safety aspects should be considered for those products?The load plate of a liftable floor scale can weigh up to 200 kilograms. Just imag-ine the damage that can cause when the holding mechanism does not func-tion properly. We use reliable pneumatic springs with our floor scales for easy opening and secure holding of the load plate. For added safety, we include ad-

Download the white paper “Floor

Scale Safety” to learn more.

• Identify risks

• Prevent hazards

• Implement safe procedures

www.mt.com/ind-floor-scale-safety-ch

“The most common hazards can be easily avoided. 80% of accidents are related to poor

scale design and unsafe handling.”

Shaowen Gary ZhengHead of Floor Scales Strategic Product Group Senior Mechanical Engineer16 years of weighing technology experience

Lost Workday Rate (LWD)

ditional locking mechanisms, such as notches or wedges that keep the scale deck in place.


X-ra

y In

spec

tion Safe Customers, Maximum Quality

Sweet Smell of Success for Soap Maker

Based in Provence, France since 1992, BEA has developed a reputation for manufac-turing unique skin-care, soap and fra-grance products which it sells directly to retailers in Germany, France and the United States. The company manufac-tures an array of cosmetic products which are Ecocert and National Organic Product (NOP) certified, including body lotions, shower gels, bubble baths, scrubs, sham-poo, deodorants and perfumes.

The company manufactures around 2,500 tons of soap every year. Quality is a core concern and the company’s ongoing commitment to improve its quality pol-

icy was rewarded with ISO 9001 certifi-cation in 2011.

Enhancing qualityIn a bid to further enhance quality, the company began exploring product in-spection solutions in 2014. As technical director Didier Vial said, “Our aim is to meet our customers’ needs precisely in terms of the shape, color, size and per-fume of our soaps, but our most impor-tant concern is product safety. Our soaps are at risk from two types of contamina-tion: first, from contaminated raw mate-rials – for example, stones from the lav-ender fields – and second, from parts of

our processing machinery. Soap manu-facturing is a mechanical process and there’s a risk that small parts of blades or screws could end up in products.”

Removing risksMr. Vial went on to explain, “Metal is the main contaminant we watch for. We once found part of a metal spring in a bar of soap, which could have been ex-tremely damaging if it found its way to a customer. At that point, we decided we couldn’t take any further risks and began to conduct tests with a variety of product inspection systems from a number of dif-ferent suppliers. It very quickly became

A French manufacturer of private-label personal care preparations recently in-

vested in x-ray inspection technology to safeguard customer welfare and stand

out from its competitors by providing higher-quality products.

clear that x-ray technology was the solu-tion we needed.”

Selecting the right solutionAfter considering many options, the com-pany purchased a METTLER TOLEDO Safeline X33 Series x-ray system. Specif-ically designed to inspect small to me-dium-sized packaged products, the X33 utilizes new detector technology which al-lows the integration of a low power (20W) x-ray generator. The system provides automatic detection and rejection of glass, metal, mineral stone, calcified bone and high-density

plastics and rubber, and it is capable of inspecting up to 300 products per minute.

Installed in January 2015, the X33 sits at the end of BEA’s production line and cur-rently inspects 50 bars of soap wrapped in plastic per minute.

The company is delighted with the impact the x-ray system has had so far, as Mr. Vial affirms. “By detecting very small contam-inants, the X33 gives us and our custom-ers the assurance that our soaps are safe which helps to differentiate us from our competitors.”

www.mt.com/safeline-xray-ch

X-ray Inspection - More Than Just Contamination DetectionFind out more about x-ray inspection technology

and how it can:

- Measure mass

- Inspect fill levels

- Check for missing components

- Check package quality

Download our white paper: www.mt.com/xray-integrity-ch

Whi

te P

aper X-ray InspectionMore Than Just Contamination Detection

Contents1 Why Use X-rays to Inspect Products?2 How Does X-ray Inspection Work?3 X-ray Inspection Sees What You Can’t See3.1 Measurement of Product Length, Width, Area, and Volume

3.2 Identification of Missing or Broken Items3.2.1 Detection of Damaged Products 3.2.2 Detection of Missing Products3.2.3 Insert Inspection3.3 Measuring Mass and Monitoring Fill Levels3.4 Product-in-Seal Inspection4 Conclusion: No Shocks or Surprises

BEA currently inspects 50 bars of soap per minute for a wide range of contaminants.

Detecting a Wide Range of Contaminants X-ray inspection technology is able to detect contaminants such as: • Metal• Glass• Mineral stones• Rubber• Dense plastic• Calcified bone


Mul

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ses Intelligent Workflow

for High Throughput Routine Analysis

Dr. Weigert GmbH, a German chemical producer based in Hamburg, manufac-tures cleaning solutions used for clean-ing and disinfecting medical instruments. The composition and quality parameters of such solutions are extremely important and must be rigorously tested. Due to the high demands of these solutions, and a re-sponsibility to their customers, Dr. Weigert was looking for an automated system to

speed up their multiparameter analyses.

A modern, multiparameter systemWith a high sample throughput, the QC lab at Dr. Weigert GmbH needed a mod-ern, fully automated system to perform multiparameter analysis with automated method selection for each sample. Depend-ing on the sample requirements, density, refractive index, acid/base number, ac-

tive chlorine content and pH can be de-termined. METTLER TOLEDO devised a system that performs all the required anal-ysis followed by automated cleaning, con-ditioning and waste management. The sys-tem also ensures secure data handling.

A DM40 density meter connected to LabX® PC software lies at the heart of the system. The density meter is con-nected to an Excellence T90 titrator, a RX50 refractive index cell and a SC30 automation unit fitted with a barcode reader. Samples are labelled with a 2D barcode on the vial and placed on the SC30, which reads the data. The Smart-Codes™ functionality in LabX automat-ically selects the correct analysis method for the sample.

Due to the high alkalinity of the chem-icals measured, contact with the density measuring-cell must be kept to a mini-mum to avoid damaging the glass. The system ensures that the density cell is

The correct composition of medical cleaning solutions is extremely important and

must be rigorously tested. For Dr. Weigert GmbH, a fully automated, multiparam-

eter system from METTLER TOLEDO performs all the required analysis, including

automated method selection, secure data handling and even solution waste man-

agement.

thoroughly rinsed as soon as the mea-surement has finished. Due to the dif-fering chemical properties of the sam-ples, the automated system ensures that waste solutions are separated and stored accordingly.

All data is stored by LabX software and analytical results are automatically transferred to a LIMS system where a plausibility check decides if results fall within specification. A task scheduler is also predefined in LabX to enable system conditioning and preparation to be per-formed at the start of the day. In this way, the system is ready for the first sample when the first operator arrives in the lab.

Fully automated and secure workflowThe multiparameter system provides a fully automated and secure workflow that includes pre-analysis condition-ing, method selection, cleaning, waste management and data handling. Pro-

Multiparameter system: T90 titrator, DM40 density meter, RX20 refractive index cell, and SC30 automation unit.

ductivity is increased, transcription er-rors eliminated and operator time kept to a minimum. All the operator has to do is press the ‘SmartCode Start’ button on the master, density meter interface and place new samples on the automa-tion unit. This means an easy, safe and very efficient quality control system for Dr. Weigert GmbH.

www.mt.com/titration-multiparameter-ch


GPro

500

Gas

Ana

lyze

rs In Situ Sensor Conveniencewith the Power of an Analyzer

Flexible installation, fast response and minimal maintenance Since their launch in 2012, the GPro 500 series (winner of a Frost & Sullivan Best Prac-tice Award) of tunable diode laser ana-lyzers have simplified gas measurement in chemical and petrochemical applica-tions across the globe. Their ease of in-stallation, speed of response, low main-tenance and flexibility to be utilized in a wide range of processes make the GPro 500 very attractive. The addition of new

analyzers to the range will widen its suit-ability still further.

GPro 500 has been available for O2, CO and moisture measurement. Now, models for O2 plus temperature, CO%, CO2%, and a combined CO2% plus CO% make the full GPro 500 portfolio suitable for many re-finery processes where paramagnetic and extractive NDIR analyzers are normally used. Some of these process applications are outlined below.

Greater catalyst regeneration efficiency in FCC units Fluidized Catalytic Crack-ing (FCC) is an essential operation in most modern refineries. FCC units break (crack) the long chain hydrocarbons in heavy gas oils into short chain hydrocar-bons to produce gasoline and fuel oils.

The catalyst used in the process must be regenerated to maintain its functional-ity. Conditions in the regenerator must be maintained in a narrow range or else the catalyst can be damaged or regeneration is not complete. Catalyst regeneration can be controlled by monitoring O2, CO and CO2.

Due to the presence of catalyst particles, narrow tubing carrying a sample can easily become blocked and extractive sam-ple cells fouled. In addition, there is a delay in measurements due to the time re-quired for sample transportation and con-ditioning.

The GPro 500 series works on the princi-ple of laser absorption spectroscopy which is a non-contact measurement technique, so no tubing is involved. And because the

The GPro® 500 series of in situ TDL gas analyzers is proving its reliability and flex-

ibility in chemical and petrochemical plants worldwide. Now, four new analyzers

plus an adaption for trace level measurements will further its range of applications.

For simple, accurate and reliable gas measurement, get the GPro 500.

GPro 500 measures in situ, measurements are almost instantaneous.

Prevent thermal runaways in ethylene oxide generation Ethylene oxide is a very important raw material with a wide range of uses in ag-rochemicals, detergents, textiles, pharma-ceuticals, etc.

Controlling O2 during production is criti-cal for safety as a level higher than around 25 % will result in thermal runaway. Therefore, speed of response and contin-uous measurement are essential. Para-magnetic analyzers not only have a long measurement time, the paramagnetic cell is delicate. If either the analyzer or the maintenance-heavy extraction equipment is off-line, the reaction is running blind.

The GPro 500 O2 sensor has a response time of less than two seconds, and other than annual verification, requires no maintenance.

Gas analysis measurement points in FCC unit.

Safer purified terephthalic acid productionPTA is mainly used as a precursor in the production of multi-purpose plastics such as PET.

The level of O2 in production off-gas is a vital measurement to prevent explosions and prevent uncontrolled oxidation. CO2 is also usually measured to provide data on reaction progress and for safety reasons.

As mentioned above, paramagnetic O2 an-alyzers are fragile, they are also expensive to replace should this become necessary. For CO2 measurement, commonly-used NDIR analyzers typically use motors and broadband IR sources which need periodic replacement.

The GPro 500 series has no moving parts. This ensures high reliability and a long operational lifetime. In addition, as both its laser source and detectors are in the sensor head, the GPro 500 does not need alignment.

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Measurementpoint GPro 500

White cell for low-range applicationsFor processes where accurate, low-range extractive measurement is required, the new White cell adaption for the GPro 500 series provides an effective path length of 10 m and boosts measurement resolution by a factor of 10.

Simple, accurate and reliable When it comes to process safety for pro-tecting the environment, people, and as-sets, only the best equipment will do. The GPro 500 offers the convenience and ease of use of an in-line sensor, combined with the performance of a powerful gas ana-lyzer. With the GPro 500, gas measure-ment across a wide range of applications is simpler and more dependable than ever before.

www.mt.com/TDL-ch


Case

Stu

dy Getting the Taste RightIntegrating a Dosing System

The leading producer of flavors and fragrances had demanding requirements when

upgrading their dosing system. It had to be safe and easy to operate, enable fast

and accurate dosing and facilitate secure handling of process data. The engineer-

ing team thought outside the box to develop a solution that was tailored to the

customer’s needs.

As the market leader with more than 30 production sites worldwide, Givaudan takes great care to ensure each batch of flavors and fragrances fulfills exact spec-ifications. A central recipe server at Givau-dan headquarters is critical in guaran-teeing accurate mixtures everywhere they are produced.

At the production site in Dübendorf, Swit-zerland, a dosing system for sub-mixes had to be upgraded following changes to the global software infrastructure. In ad-dition, the existing METTLER TOLEDO weighing terminals were coming to the end of their service life after 14 years of reliable performance.

Challenging requirements“We discussed three key requirements with the METTLER TOLEDO engineer-ing team,” says Tom Schmid, production manager at Givaudan. The dosing solu-tion needed to match the existing elabo-rate setup, ensure secure transmission of recipe and process data and facilitate safe and efficient operation.

At the first station, four materials are dosed semi-automatically into large-vol-ume mobile vessels on a high-precision floor scale. A second, more complex, dos-ing system consists of two tanks on high-precision floor scales with natural and synthetic acetaldehyde.

These chemicals are either dosed semi-automatically into large-volume mobile vessels (loss-in-weight) or manually into small-volume vessels (gain-in-weight) on a separate small-capacity scale to ensure measurement accuracy.

Smart solutionThe IND560xx weighing terminals in-stalled by METTLER TOLEDO are de-signed for hazardous area ATEX Zone 2 and provide extensive functionality to cus-tomize the dosing application. Operators

are identified and guided through the dos-ing process to ensure safe operations. Ad-ditional features help ensure accurate and safe dosing processes, for example, to pre-vent over- or under-filling, to detect if ma-terial is missing or to ensure that a filling vessel is present.

“This was an exciting project for us because

Givaudan had several unique specifications that called for

our full creativity,”

Seamless connectivity“To facilitate communication with the central server at Givaudan headquarters, we proposed to develop a virtual applica-tion server,” says Jürg Binkert, a METTLER TOLEDO engineer. Each of the weighing terminals is connected via Ethernet to the application server. Based on the production order number, the respective recipe position is pulled from the central server with the relevant dosing parameters. After dosing, the corresponding process data is trans-ferred back to the central server.

“This was an exciting project for us be-cause Givaudan had several unique spec-

Application: acedaldehyde dosing • Two dosing stations on the first floor – one

loss-in-weight for large volumes and one gain-in-weight for small volumes

• Two storage tanks on high-precision floor scales located on second floor

• Control via IND560xx weighing terminals with Ethernet connection to application server

Benefits:• Safe and accurate dosing on both large- and

small-volume dosing stations• Accurate control of material inventory regardless

from which station it was taken• Real-time traceability of order process and material

consumption connection to application server

ifications that called for our full creativ-ity,” Binkert says. Schmid agrees that the partnership yielded positive results. “We like to work with METTLER TOLEDO be-cause we get a solution that is really tai-lored to our needs,” he says.

The installation has proven successful in daily operations and has meanwhile been adopted by the Givaudan site in Dort-mund, Germany, for six dosing systems.

www.givaudan.com www.mt.com/ind560x-ch

Pictured above is a cluster dosing system for four materials on a high-precision floor scale.

A tank rests on a hazardous-area approved high-precision floor scale for accurate dosing of acedaldehyde.

Synthetic Acedaldehyde

Natural Acedaldehyde

IND560xx weighing terminal

Safety valves

Control valves

Large and small volume dosing of Acedaldehyde.

Seco

nd F

loor

Firs

t Flo

or

Precision weighing platforms

For more information

www.mt.com/ind-ch

Mettler-Toledo GmbHIndustrial DivisionCH-8606 Nänikon, Switzerland

Local contact: www.mt.com/contacts

MTSI 30302335

Are You Testing Enough?Or Too Much?

Minimize risks and reduce costs• Optimize your routine testing to ensure consistent weighing results.• Save costs by eliminating unnecessary tests. • Assure traceable documentation including testing procedures and frequencies.

Improve Your Scale Testing www.mt.com/gwp-verification-ch

ISO9001 requires that weighing equipment must be calibrated and verified at defined intervals. But how

those tests should be done or how often is not specified. Our GWP® Verification service provides testing

recommendations based on your process requirements.

safety first beware of hidden hazards · sible hazards in a timely manner. the chemical industry...

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