PC-JUN24-PG16-17.1_Layout 1 17/06/2024 08:51 Page 16


PACKAGING


COMBINED SYSTEMS CONTROL COSTS Neil Gruettner, Business Development Manager, Vision Inspection, Mettler-Toledo, looks at the complexities of carton packaging applications, and explores how combination product inspection can combat rising costs


C


arton applications are the backbone of diverse industries, from biscuits and tea bags, to pasta and baked goods. However, with escalating costs and stringent regulations, manufacturers encounter significant challenges in maintaining efficiency and accuracy in carton packaging. The implications of errors in carton applications are not merely financial; they extend to operational efficiency, resource management and brand integrity. Operation checks, traditionally conducted through sample checks, are inherently limited and expensive. The more production lines a manufacturer operates, the higher the costs associated with manual checks, amplifying the financial burden.


Moreover, the timing of error detection


significantly impacts cost. Delayed recognition of quality issues results in increased waste and higher expenses. When non-conforming products are identified late in the supply chain, the consequences worsen. Recalls become inevitable, leading to costs in terms of product retrieval, rework and potential fines.


Labelling errors and incorrect fill levels stem from various sources, including operational errors and equipment malfunctions. These errors not only result in regulatory non-compliance but also jeopardise product quality and consumer safety.


The repercussions of non-conforming product entering the marketplace result in recalls, but potentially also harm the end consumer. Product recalls not only incur


direct financial expenses but also carry the risk of substantial fines from retailers, often amounting to billions, or loss of contracts. Furthermore, recalls inflict severe damage to brand reputation. Consumer trust is eroded, resulting in altered buying behaviours and decreased turnover. The combination of high costs and brand damage creates a detrimental cycle, further exacerbating financial losses. In essence, the financial toll of errors in carton applications extends far beyond immediate expenses. Delayed error detection amplifies costs, diminishes brand value and erodes profitability, underscoring the critical importance of proactive quality control measures.


Filled cartons must meet stringent weights and measures legislation, such as pre- packaged goods legislation, for accurate measurement and labelling to maintain fair trade practices. Regulatory requirements, including the EU Directive 1169/2011, US Food & Drug Administration (FDA) regulations and Natasha’s Law Guidance in the UK, mandate precise labelling of product contents, nutritional information and allergen warnings, crucial for consumer safety and transparency. Compliance with these regulations is imperative to protect the consumer against incorrect labelling, avoid severe penalties, and preserve brand reputation.


Manufacturers must employ robust quality control measures, including inspection systems, to facilitate adherence to regulatory standards and mitigate risks associated with


MAXIMISING THE BENEFITS OF COMBINATION INSPECTION SYSTEMS


Combination inspection systems offer many advantages, including: Lower Total Cost of Ownership: Shared components streamline maintenance and reduce costs, while service by a single technician minimises downtime. Space Saving: Combined inspection devices are more compact than individual units, optimising floor space in production facilities. Enhanced Operator Efficiency: User-friendly Label Inspection software simplifies operation, eliminating the need for extensive coding expertise. Product changeover is streamlined, as adjustments are made on one device only. Advanced Software Options: Feedback Control options fine-tune filler behaviour for more accurate fill levels, reducing costly product giveaway and enhancing efficiency. Additional Layer of Transparency: By connecting to data management software ProdX™ all inspection data is recorded in real-time, stored, and easy accessed. Adding a layer of transparency to the production process, this data can be used to improve production flow control measures, detect anomalies such as weight discrepancies, support compliance efforts and facilitate auditing efforts.


16 JUNE 2024 | PROCESS & CONTROL


non-compliance, safeguarding both consumer safety and market competitiveness.


So, the next logical question is what can manufacturers do? There are three easy steps to combat rising costs in carton applications:


1. 100% Automated Inspection: Transitioning from manual spot checks to fully automated inspection processes of cartons reduces costs significantly while enhancing accuracy and efficiency.


2. Earlier Detection: Integrating inspection systems at an early stage in the production process of carton applications means errors are identified and rectified promptly, minimising downstream repercussions. 3. Combination Inspection Solutions: Leveraging combination checkweighing and vision inspection systems offers a comprehensive approach to quality control of carton applications, reducing the total cost of ownership and enhancing operational efficiency.


Putting the above into practice, manufacturers can implement a “gatekeeper” of sorts, in the form of a combination inspection system. This smart solution integrates checkweighing and vision inspection functionalities, providing 100% automated inspection to detect errors promptly. By serving as a comprehensive quality control checkpoint, inspecting each filled carton in real-time, at high production speeds, the combination system acts as a safeguard against costly errors and meets compliance with regulatory standards. Benefits of Combination Inspection • Streamlining: Combination inspection systems provide numerous benefits. These systems are designed with shared components, streamlining maintenance efforts and reducing the need for duplicate parts. By consolidating inspection functionalities into a single unit, manufacturers benefit from simplified maintenance procedures and decreased costs associated with component management.


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56