Test & measurement
as machines drift over time or respond to subtle changes in product flow.
Fill level adjustment addresses this by creating a feedback loop. As the checkweigher gathers real- time data, it adjusts the filling system automatically to maintain a tighter, more predictable package weight. This not only reduces giveaway but also supports greater line stability, especially during changeovers or when dealing with variable product formats.
MAKING SMARTER USE OF EXISTING TECHNOLOGY
One of the strengths of modern fill level adjustment is that it does not require a complete overhaul of the line. In many cases, it can be integrated into existing checkweighers and filling equipment with a software upgrade and some configuration support. That makes it a cost-effective and scalable option for manufacturers looking to boost performance without introducing complexity.
“On average, the investment is recouped within a month or a few months, depending on the product and the line,” says Frank Borrmann, market manager for the Strategic Business Unit Checkweighing & Vision, Mettler-Toledo Garvens GmbH. “Companies realise that they can save a lot with smart technology.”
The return is not only financial. By reducing reliance on manual intervention, the system also supports consistency, frees up operator time and lowers the risk of human error. As many manufacturers face labour shortages or shifting staffing patterns, this level of automation helps build resilience into the process.
REAL-WORLD IMPACT
At Greenyard Frozen Belgium, which produces millions of frozen fruit and vegetable packs each year, fill level adjustment has already delivered measurable improvements. One of its packaging lines reduced excess weight from 0.69 percent
to 0.14 percent. On another, the figure dropped from 0.3 percent to 0.11 percent. Those numbers translate directly into reduced waste, lower costs and more efficient use of materials.
“That may not seem like much, but if you calculate it on an annual basis over large volumes, you are talking about considerable quantities of product that you no longer unnecessarily pack,” says Dominiek Vierstraete, technical manager at Greenyard. “That is beneficial for the cost price and for reducing waste.” The company now uses fill level adjustment on all six of its small pack lines, a move that supports both sustainability goals and operational consistency.
LOOKING FORWARD
As material costs remain volatile and consumer expectations continue to rise, manufacturers will need to find new ways to optimise their processes without compromising quality. Fill level adjustment offers a clear path forward. It addresses a known source of waste, requires minimal disruption to implement and can unlock performance gains almost immediately.
The technology is also evolving. As communication between systems becomes more streamlined and visual interfaces improve, operators gain even more transparency into line performance. “You can immediately see how the average weight develops via a visual interface,” said Vierstraete. “After a few hours of testing and adjustments, the system runs stably.”
For manufacturers ready to take tighter control of their line efficiency, fill level adjustment is no longer a niche add-on. It is fast becoming a standard expectation in high-performing production environments.
Mettler-Toledo Garvens
www.mt.com
Instrumentation Monthly October 2025 29
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