FOOD & BEVERAGE
40th Anniversary 40yrasrevinnAht0 4 FINE TUNE YOUR PRODUCTION
Charlie Graham, European sales manager, Sparc Systems, suggests the data generated by advanced
checkweighers is better than having your own crystal ball! Here he explains why...
C
heckweighing technology has evolved rapidly in recent years. Beyond inspecting under and overweight filled
packages and ensuring compliance with net contents laws, the adoption of automated adjustments and data capture software means checkweighers can be the source of information that drives untapped ROI. The global market outlook for automatic
checkweighers is strong, with industry reports predicting a rapid growth of approximately 4.6% CAGR each year between 2019 and 2027. This may be down to a number of factors, from awareness among FMCG manufacturers about the benefits of checkweighing technology to strict regulatory mandates for packaging of food products. And yet, there is still plenty of untapped
potential for the utilisation of automation and data collection at this critical point in the food production process. More modern machines have refined the process beyond achieving high speeds, providing feedback data needed for quality control and interfacing with other machinery to make adjustments autonomously. When used in the right way, the upfront cost of a checkweighing machine will soon provide a return on investment. Greater efficiency can be achieved using
current network techniques, with high-speed communication technologies such as a secure Ethernet integrating checkweighers into groups. These results can be pooled across multiple lines of identical product groups and pack sizes to calculate an average batch weight. This means one line can augment the results of another. For example, if one system has an average
weight below the declared quantity of a product, taken alone the checkweigher would have to reject packs to bring that average up. However, virtual checkweighing allows this machine to be complemented with another unit that is running with a high average weight. Upon inspecting each pack, the
34 DECEMBER 2020/JANUARY 2021 | PROCESS & CONTROL
checkweigher broadcasts the average weight so far in the batch. Concurrently, it listens to the broadcasts via an Ethernet local area network from the other units of the same group. The checkweigher then calculates the average weight of the group and automatically decides whether or not to reject each pack based on overall performance. The result? A reduction of unnecessary rejects and subsequent wasted product. Lower factory yield due to repeated false
rejects frequently undermine the cost- effectiveness of an entire operation, while repeated stoppages and trouble-shooting will incur unnecessary costs. Besides reducing false rejects and product waste, the use of modern network technologies allow for automatic data transmission. With integrated data collection software, everything from trends, pack rates and live OEE data is instantly reported. Production and QA personnel can then utilise the information to monitor and fine-tune production line performance, even prior to the weight check process. As an example, if a meat manufacturer
finds inconsistencies in the size of meatballs, this indicates that the processing machinery is not running accurately. Beyond highlighting this fault, precision systems, such as Sparc’s Sentinel checkweigher, provide a controlled feedback signal to upstream automation
equipment used to portion food products. This signal specifies when to increase or decrease the fill quantity accordingly, eliminating the need for human intervention. These benefits are made all the more
prevalent when integrated with existing or combined inspection technologies such as metal detection and x-ray. Combination systems bring food factories one step closer to the vision of a smart factory, whereby connected devices work alongside each other to reduce contamination, ensure food safety compliance and boost traceability and efficiency. With this vision in mind, Sparc recently assisted in the collaboration with Fortress Technology to unveil the Raptor Combi - a flexible, fast and affordable fully integrated checkweigher and metal detector. The Raptor’s universal design gives
manufacturers the option to purchase a standalone Sparc checkweigher, and attach a complimentary Fortress Stealth metal detector at a later date to meet different phases of a production and inspection investment strategy. Flexibility is also important to consider when
specifying checkweighing technology - and is one where smart, automated features can help. As well as retailer COP parameters, an HMI touchscreen panel used to calibrate numerous inspection machines within the same food factory addresses the increased need for visual packaging control due to smaller batch sizes and the avoidance of mistakes during product switchovers. Integrated technology that provides access
to machine functions with the click of a button reduces the changeover time of different products, pack sizes and formats while ensuring consistent compliance with international weight and measurement standards.
Sparc Systems
sparc-systems.com
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