INDUSTRY UPDATE
to suit particular products and environments. A differential control, with an amplification factor, is crucial for cases of extreme overfilling or underfilling. In such a circumstance, the operator must be able to decide the level to which the filler is controlled, based on a particular measurement series, to bring large deviations under control more quickly, thereby saving unnecessary product loss. Extended feedback control allows the operator to do this with ease, cutting costs and increasing profit in previously unreachable areas of the production line. For example, in the packaging process, manufacturers need to prevent both overfilling and underfilling of dry bulk products such as tea, flour, sugar or spices. Directly connecting a checkweigher to the packaging machine will proactively control the filling process of the bags. Similarly, the two control factors feature allows greater flexibility than standard feedback control functions. With this feature, the correction of either overfill or underfill can be prioritised by setting different manipulated variables and catering to production lines where underfilled products are recycled into the process, as well as those where these are scrapped. Saving product waste is the key to advanced feedback control: reducing costs through a truly flexible, adjustable system.
Time is money Saving on product loss is good for a company, but it must not come at the expense of line speed. If brands are to increase profit in a competitive market, decreasing downtime and boosting throughput of packaging lines is an excellent place to start. Innovative feedback control functions must therefore be developed to increase productivity and should be easily integrated. One of the essential features of feedback control is that it carries out tasks automatically and constantly
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An essential feature of feedback control is that it carries out tasks automatically and constantly throughout the filling & weighing processes, with all functions making quick corrections during and throughout product runs. throughout the filling & weighing processes, with all functions making quick corrections during and throughout product runs. Likewise, the ability to modify correction speeds and preferences means that companies can fine-tune their parameters in a shorter period of time compared to that with a standard feedback control. By refining these processes for the highest possible line speeds, this advanced feedback control can make a real difference on a firm’s balance sheet. Speed is of equal importance when integrating a new checkweigher or add-on into an existing setup. Highquality customer service is an absolute must to ensure that no time is lost as a result of preventable complications. For example, companies making the switch to advanced feedback control must be advised and aided in the arrangement and layout of their packaging line, typically placing the checkweigher as close as possible to the filler.
Protecting the brand It is absolutely crucial that any feedback control function allows brands to comply with industry Weights and Measures guidelines, and avoid the fines and loss of consumers’ trust that might result from breaking regulations or shipping underweight products.
Switching to an innovative feedback control function is a guaranteed way of avoiding the unwanted attention of regulators, and upholding consistently high quality. After production commences, the target weight is automatically adjusted (a proactive function not possible with standard feedback) to make full use of the permissible range. This function ensures that customer rights are observed at all time, and brands are able to avoid the eventuality of costly legal actions. Extended feedback systems can also help meet legal requirements without the cost of losing optimum efficiency. A proactive optimal overfill feature can take into account the fact that a certain production percentage (2 per cent) is allowed to fall below the set limit for that product, and adjusts the filler accordingly. It is this attention to detail that can help manufacturers get a welcome head-start on their rivals.
A sure winner The success of a modern checkweighing system is, to a large extent, inherent to the finer details. Innovative feedback control has the capability to take checkweighing to new heights. Through such a system, the checkweigher and filler work in sync to achieve the best possible results and extremely smooth filling process, irrespective of the specificity and evolution of these requirements. Gunter Schilpp, Head of Product Management, Mettler Toledo Garvens, is into global marketing activities in the field of checkweighing applications and solutions at the company. With over 14 years of experience in the packaging industry, he is responsible for transforming complex technical issues into clear customer value messaging, global solution launches, market strategy development, research & checkweighing development collaboration as well as brand strengthening & marketing strategy creation. Email: gunter.schilpp@mt.com
Modern Packaging & Design May-June 2011