20News

Bulk Foods

Legislative compliance can be a challenge, but weighing and monitoring equipment can make

it easier to pass your next audit and prevent product failures from entering commerce. We

share the top four ways to meet regulations and prevent problems before they happen.

Problem Prevention4 Ways to Manage Quality

Weighing and foreign-body detection are often part of bulk goods, production equipment. How can the right weigh-ing solutions help support compliance? There are at least four ways in which you can use weighing and foreign-body detec-tion solutions to become more efficient in managing quality and staying complaint.

1. Reduce risk of foreign bodiesAll regulations require activities to reduce the risk of foreign bodies. You will be held accountable to minimize the risk of for-eign-body contamination or mislabeling that affects food safety.

The use of metal detection, X-ray inspec-tion, checkweighing and vision inspection

Recent legislative changes for bulk food producers focus on preventative controls, corrective actions and equipment main-tenance. This seems to be a global trend. In the United States, the Food and Drug Administration’s Food Safety Modern-ization Act (FSMA) includes Preventive Controls for Human Food. Those con-trols parallel the Hazard Analysis and Critical Control Point programs from the Global Food Safety Initiative (GFSI) based schemes, such as BRC, IFS or SQF. For ex-ample in the FSMA, all risk-based process preventive controls are monitored, veri-fied and validated. In the British BRC or in the German IFS standards, the risks are identified and addressed in the Food Safety Plan.

Industrial Weighing & Product Inspection

METTLER TOLEDO Bulk Foods News 20

The Strictest Quality Control ProgramCheckweigher Ensures Compliance

Inspection of packages to ensure correct weight and freedom from metal contaminants

is critical for a leading cereal producer. The company has installed product inspection

systems to ensure customer satisfaction and support compliance with leading food-

safety standards.

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Metal contaminant detectionAll packaged products are screened for metal contamination immediately after the checkweighing process using a METTLER TOLEDO Safeline metal de-tector. The system detects all metal types, including difficult-to-find non-magnetic stainless steels. Non-compliant packages are automatically removed from the pro-duction process using a fully-automated pusher system. The inspection devices support IFS compliance and are desig-nated as a Critical Control Point (CCP) in the quality program.

www.mt.com/pi-bf

The range of oat-based cereals and snacks produced by Peter Kölln KGaA has increased considerably in recent years. The German company operates a strict quality control program in accordance with the highest food-safety standards. As such, their quality management system is certified in accor-dance with DIN EN ISO 9001. That is com-plemented by certification with the Inter-national Featured Standard for Food (IFS).

100 percent inspectionOn the muesli production line, an XE3 checkweigher from METTLER TOLEDO inspects every carton on a high-speed production line to ensure consumers re-

ceive the correct amount of specified contents. The checkweighers are ideally suited for use in bulk-food production en-vironments and support compliance with local and international Weights and Mea-sures legislation.

Flexible and versatileThe easy-to-operate system allows for rapid set-up and changeover between product batches, carried out at speeds of over 140 packs per minute. Fast product changeover is particularly important for a company that inspects up to 14 differ-ent products with weights ranging from 325 grams and 1 kilogram.

METTLER TOLEDO Bulk Foods News 20

Com

plia

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reports from software verifies all preven-tative measures.

www.mt.com/ind-food-regulatory-guide-bf

can assist food processors with all compli-ance matters.

2. Increase traceability in tank weighingModern weigh modules that are used for tank- or truck-weighing applications not only offer high accuracy, but also can be an integrated part of a safety plan by au-tomatically providing weighing results. In combination with the right terminal, all results can be safely stored or printed. Knowing the exact amount of incom-ing and delivered goods increases process traceability.

3. Tools for corrective actionsMonitoring software connected to weigh-ing equipment delivers clear guidance for corrective action plans. Software, such as CollectPlus, helps you constantly moni-tor the weighing results from tank scales and offers a graphical indication of the tank-weighing status. Trends are visi-ble quickly and corrective actions can be taken accordingly.

4. Maintenance and calibration Regular maintenance that includes equipment calibration clearly reduces risk of equipment downtime. During sit-uations when equipment downtime is unacceptable and risks to product qual-

ity are imminent, predictive diagnos-tics tools, such as POWERCELL® PDX® technology helps to prevent damages be-fore they occur. Finally, documented cal-ibration performed by a certified cali-bration service provider and statistical

2

Publisher / ProductionMettler-Toledo GmbHIndustrial DivisionHeuwinkelstrasseCH-8606 NänikonSwitzerland

Subject to technical changes© 02/2017 Mettler-Toledo GmbH

2. Tank-Weighing ModulesSWB505 MultiMount™ weigh modules pro-vide accurate weight results to increase traceability and keep production managers in control of their process.

1. Foreign Body DetectiontFor metal detection, special gravity-fall sys-tems can be used for bulk granular prod-ucts from fine, dusty powders to products with irregular particulates.

4. CalibrationWith regular scale calibrations and ad-justment, manufacturer ensure compli-ance and avoid the costs of inaccurate measurements.

3 Tank Weight MonitoringCollect+™ data-collection and visualization software captures any weight data, high-lights process deviations and enables qual-ity managers to take corrective actions.

4 Ways to Manage Quality

METTLER TOLEDO Bulk Foods News 20 METTLER TOLEDO Bulk Foods News 204 5

UV/V

IS S

pect

rosc

opy Quick Quality Control of Olive Oil

with UV/VIS Spectroscopy

True extra virgin olive oil is touted for its health benefits as it is rich in vitamin E,

antioxidants and monounsaturated fatty acids. UV/VIS spectroscopy provides a fast

analytical method for the classification of olive oil quality according to interna-

tional standards and is able to reliably unveil product falsification.

This is illustrated by the UV/VIS spectra for two oils of different qualities in Fig-ure 1. The spectrum of the extra virgin oil (blue) shows a notably weaker absorp-tion in the 200 to 300 nm range compared to the olive oil with no quality declaration (green). The quantitative evaluation and assessment of the individual K values in accordance with the IOC norms confirm the olive oil declaration.METTLER TOLEDO’s UV5 spectropho-tometer is the ideal instrument for de-termining the quality of olive oil. Due to

What causes olive oil quality to differ?Olive oil of low quality contains sub-stances that are formed as a result of degradation processes, and, unlike high quality olive oil, absorbs UV light within the spectral range of 200 to 300 nm. This discrepancy is explained by the pres-ence of unsaturated fatty acids with differ-ing chemical structure and UV absorbance characteristics in the higher quality olive oil, where degradation compounds are hardly present. Such difference provides the basis for the spectrophotometric test examining the quality of olive oil: low ab-sorption between 200 to 300 nm is a mea-sure of high quality extra virgin oil, while high absorption reflects an olive oil of lower quality.

Easy and fast verification of olive oil quality using UV/VIS spectroscopyThe International Olive Council (IOC) de-fined three key criteria that must be met before an olive oil is branded as extra vir-gin. The criteria are based on the extinc-tion coefficient K at four different wave-lengths (232 nm, 266 nm, 270 nm and 274 nm).

the FastTrackTM technology, measure-ment results are achieved within seconds. The equations necessary for the param-eter calculations according to the IOC quality classification can be defined eas-ily. Limits can be set up for each calcu-lated parameter so that deviations are clearly displayed on the touchscreen.

Furthermore, automation with the Cu-vetteChanger greatly increases productiv-

ity by allowing for the unattended analy-sis of up to 7 olive oil samples, including a blank. Where many different olive oil samples need to be analyzed, LabX® UV/VIS software facilitates the measurement workflow and management of results.

Results are securely stored in the data-base and can be unambiguously tagged in order to differentiate between varying olive oil qualities. Individual tolerance levels automatically support immediate result assessment, and control charts en-

able trend analysis of samples over a de-fined period of time. In addition, UV/VIS spectra can be individually annotated, re-sults re-evaluated or re-calculated if re-quired and reports can be individualized according to customer preferences.

} www.mt.com/uv-vis-bf

Figure 1: UV spectra for the two olive oil samples dissolved in cyclohexane to a 1% solution (blue: extra virgin quality, green: no quality declaration).

Wavelength [nm]

0.0220 240 260 280 300 320 340 360 380

0.5

1.0

1.5

2.0

2.5

Abso

rban

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Olive oil with no quality declaration

Extra virgin olive oil

METTLER TOLEDO Bulk Foods News 20 METTLER TOLEDO Bulk Foods News 206 7

Will your truck scale give you the 20 years of service that you expect? Most truck scale

manufacturers answer that question with promises they cannot back up. Only one manufac-

turer gives you real proof that your truck scale can handle more than a million vehicles.

Like many weighbridge manufacturers, METTLER TOLEDO uses computer cal-culations and finite-element analysis to evaluate weighbridge designs. While this testing can provide valuable information about areas of high stress, it is strictly the-oretical. It does not indicate how well a

weighbridge will meet the real-world de-mands of vehicle weighing.

When other manufacturers talk about the longevity or durability of their weigh-bridges, they are using guesswork. They have no data to back up their guesses. With a new weighbridge design, the best they can do is install it at a customer’s site and wait years to see how long it survives. In essence, their customers test weigh-bridges for them.

Proven performanceMETTLER TOLEDO is the only manu-facturer that tests how well its weigh-bridges perform. Every design is sub-jected to the weight of 1 to 2 million fully loaded trucks.

For each new design, an actual mod-ule undergoes accelerated-life-cycle test-ing on our “module masher” test stand. The first “module masher” was designed and built in 1992 by the engineering and manufacturing teams at our heavy-ca-pacity manufacturing plant in the United States. No other manufacturer has any-thing like it.

A truck scale is a big investment that will affect your business for decades. If the weighbridge fails after a few years of use, your budget will be hit with replacement costs that are both unexpected and ex-pensive. To get the best return on your investment, demand a weighbridge with proven longevity.

Proven DurabilityThe Strength to Weigh a Million Trucks

Life

-Cyc

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The test stand uses hydraulically oper-ated feet to apply forces up to 120 000 pounds (54 430 kilograms). Attached to the bottom of each foot are two rubber pads that approximate the footprint of a pair of truck tires. For a typical test, the hydraulic feet are positioned to simulate the load applied by a dual-tandem truck axle. Each time the feet press down on the weighbridge, they exert the same force as a fully loaded truck.

Real-world testingThe standard procedure involves two stages: stress testing and life-cycle test-ing. During stage one, strain gauges are attached at key locations on the weigh-bridge. Then loads are applied in different locations to check the stress levels across the entire module.

Stage two simulates the amount of traffic that would pass over a weighbridge dur-ing its expected service life. The “mod-ule masher” repeatedly applies the max-

imum load for which the scale is rated. One load/unload cycle requires 3 seconds.

It takes about 2 months to complete 2 million cycles, the equivalent of 2 mil-lion fully loaded trucks driving across the weighbridge. The size of the load and the number of times it is applied will depend on which weighbridge model is being tested.

No weighbridge leaves our plant unless the design has passed a rigorous life-cy-cle testing program. Using the “mod-ule masher,” we verify that each weigh-bridge we make meets design standards. It is your assurance that your truck scale is durable enough to stand up to the real-world demands of vehicle weighing for a full service life.

See the Module Masher in Action

Watch this short video to see how METTLER TOLEDO verifies the durability of its truck scales. The module mash-er applies the equivalent of 20 years of vehicle traffic to actual scale modules, giving you the confidence that your scale will stand up to the real-world demands of vehicle weighing.

www.mt.com/weighbridgetesting-bf

When you buy a scale that has not passed life-cycle testing, you risk having to pay to re-place a weighbridge due to premature failure.

METTLER TOLEDO Bulk Foods News 20 9METTLER TOLEDO Bulk Foods News 208

detector into indicating the product con-tains metal resulting in a “false reject” event. The Profile Advantage system uses multi-simultaneous frequency technol-ogy, which is able to increase detection sensitivity to metallic contaminants by up to 50 percent compared to conventional metal-detection systems.

Higher level certificationZentis was awarded Higher Level certifi-cation when audited against the Inter-national Featured Standard for Food. All inspection process data can be accessed directly from the metal-detection system, which provides valuable information to support process optimization.

Improved productivityIn addition to comprehensive support of quality management, the Profile Advan-tage also increases productivity for Zentis. Its intuitive clustering technology enables one product setting to be used for multi-ple products. That approach simplifies op-eration and shortens the setup time when switching products on the line.

www.mt.com/md-profileadvantage-bf

Understanding Challenging Applications for Improved Metal Detection

Find out more about the challenges of the product effect and inspecting wet, conductive products.

Download our White Paper: www.mt.com/md-advantageplus-bf

Whi

te P

aper

Understanding Challenging Applications for Improved Metal Detection

Contents

1. How a Metal Detector Works

1.1 Balanced Coil System

1.2 How Metal Affects the Balance Condition of the Metal Detector

1.3 Magnetic Fields, Conductivity, Permeability and Eddy Currents

2. Product Effect Explained

2.1 Factors that Influence Product Effect

2.1.1 Moisture Content

2.1.2 Temperature

2.1.3 Size and Shape of the Products

2.1.4 The Position and Orientation of the Product Through the Detector

2.1.5 Consistency and Density of the Product

2.1.6 Packaging Material

3. What is a 'Dry' Product?

4. Dealing With Product Effect

4.1 Low Versus High Frequency

4.2 Phase Discrimination

4.3 Multi-Simultaneous-Frequency Metal Detectors

5. Summary

SAFELINEMetal Detection

High-moisture products are notoriously difficult to inspect for metal contaminants.

Multi-simultaneous frequency technology has been proven to significantly increase

levels of detection sensitivity.

The Profile Advantage metal detection system inspects moist pineapple chunks on an open bulk conveyor belt. The pine-apple pieces are shaken onto the con-veyor belt and guided through the detec-tor. Any small particles of metal found in the product, which could come from the cutting process, are rejected at the point of inspection.

That is achieved through the use of an automatic belt-reversal system, which changes the direction of the conveyor belt when metal is detected. The con-taminated product is deposited into a reject catch bin behind the product in-feed chute. When the belt is reversed, the

With production facilities in Europe and the USA, fruit processor Zentis has been operating since 1893. Its fruit prepara-tions are used in yogurts and a wide range of jams, preserves, sweet spreads and con-fectionery products. The products are sold worldwide.

Consistent qualityTo ensure consistently high quality, Zentis uses a comprehensive quality-assurance system that checks raw materials through to the inspection of finished goods. An important element of the quality system is a metal-detection system used to detect and remove foreign bodies from the pro-duction process.

50% Greater Detection Sensitivity Even for Challenging Moist Products

Met

al D

etec

tion

product infeed stops to prevent unneces-sary product loss. Once the contaminated product is rejected from the belt, the con-veyor direction changes again and pro-duction resumes.

The company has been able to signifi-cantly improve process reliability by in-specting product at the goods-inwards point in the process.

A challenging applicationWet or conductive products are notori-ously difficult to inspect for metal con-taminants due to a phenomenon known as “the product effect.” It occurs when the moisture in the product fools the metal

Profile Advantage metal de-tectors attain high levels of detection sensitivity, particu-larly when inspecting wet or conductive products.

Metal-free pineapple is further processed and dispatched.

METTLER TOLEDO Bulk Foods News 20 METTLER TOLEDO Bulk Foods News 2010 11

InPro 4800 i pH electrode

“Simplicity and Savings”Intelligent pH Sensors at a French Refinery

Inte

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rs

In beet refining, reliable pH measurements are central to producing a high yield of good

quality sugar. A combination of high-performance pH electrodes and Intelligent Sensor

Management technology provides the perfect solution for Lesaffre.

ate that can clog equipment. “Sugar pro-duction from beet is a highly fouling pro-cess that occurs at high temperatures. There is the difficulty of measuring pH,” says Mr. Dezusinge. pH control is so criti-cal for effective juice purification that the measurements are often doubled to se-cure the process, as is the case at Lesaffre.

High maintenance costs of antimony probesFor the pH measurement itself, Lesaffre was using antimony pH sensors with a motorized scraper ring that would period-ically remove fouling from the probes. Mr. Dezusinge was unhappy with the costs of

A family-run refineryFounded in 1873, the Lesaffre Sugar Re-finery in Nangis, France is an indepen-dent company that has been in the Lesaf-fre family since 1882. Each year, between September and December, 8 500 tons of sugar beets arrive daily at the refinery to be converted into sugar, syrup, molasses, pulp and pellets.

After arriving on site, the beets are washed and cut into thin slices (cossettes) in order to facilitate juice extraction. This is followed by a diffusion step during which the sugar content in the cossettes trans-fers to hot water. Milk of lime and calcium hydroxide is then added to the diffusion juice to form calcium carbonate and to isolate certain impurities. Two carbon-atations, each followed by filtration, com-plement the liming. After the second fil-tration, the obtained clear juice is then decalcified and evaporated to form crys-tallized sugar.

A process prone to clogging pH probesFor high yield production of good sugar, various parameters must be monitored and controlled during the processes. Ac-

cording to the refineryʼs production man-ager, Mr. Laurent Dezusinge, “pH mea-surement is a key parameter, in particular during the diffusion and carbonatations.”

In the diffusion water, tight control of pH is important to maintain the acid-ity required for maximizing cossette per-meability, and to prevent bacterial con-tamination. This stage happens at high temperature with a strong presence of sul-fur and many deposits that can make pH measurement problematic.

Liming and carbonatation are the two most critical stages of beet refining, but generate a great deal of calcium carbon-

maintaining the motorized parts and was concerned that antimony electrodes could become obsolete. He required a better so-lution and drew up a list of requirements:• Repeatable and reliable results

with an accuracy of 0.25 pH units• Simple installation and configuration• Easy maintenance with

less sensor cleaning• Long sensor life to reduce costs

A sensor designed to tolerate sugar processesMETTLER TOLEDO proposed to Mr. De-zusinge a complete measurement system based around our InPro 4800 i pH sen-sor. This electrode is equipped with a very long diffusion path in a double electro-lyte chamber and a PTFE-coated junc-tion. Thanks to these characteristics the InPro 4800 i exhibits very good resistance to sulfur contamination, temperature tolerance up to 130 °C, and due to the PTFE coating of the junction, measure-ments are ensured even in the most sticky environments.

ISM® is the icing on the cakeAnother feature of the sensor, Intelligent Sensor Management (ISM), provides addi-tional valuable benefits:• High signal stability due to dig-

ital communication between sensor and transmitter.

• Dynamic Lifetime Indicator continu-ously monitors sensor condition and predicts when replacement will be required.

• Adaptive Calibration Timer estimates the time remaining before the next calibration should be performed.

• iSense PC software enables sensor cal-ibration away from the process in any convenient location and provides cal-ibration reports in PDF format.

Greater process reliability and less maintenanceFollowing a very successful test period, the METTLER TOLEDO solution was in-stalled in place of the old equipment. Now, compared with the previous systems, maintenance is much lower, calibration

is simplified and pH-critical processes are running with greater reliability.

Mr. Dezusinge appreciates not only the performance of the InPro 4800 i sensor, but also the ease of use of the ISM plat-form and the reduced operating costs it realizes. He said, “I can summarize the ISM approach in two words: simplicity and savings.” He has since decided to in-stall the METTLER TOLEDO solution to replace all pH measurements at the plant.

www.mt.com/InPro4800-bf

www.mt.comFor more informations

No SurprisesReal-time Equipment Monitoring

Don’t wait for Industry 4.0 to happen. Start monitoring the performance of your weighing equipment today with InTouchSM Remote Services. Connected scales send proactive alerts that enable you to immediately respond to performance issues.

Increase uptime and ensure consistent measurement quality.

For more information about Real-time Equipment Monitoring visit:

www.mt.com/ind-intouch-remote-bf

Security without Compromise• ISO27001-2013 certification• User authentication and access

control• No changes to existing IT

or security infrastructure

Efficient Equipment Management• Real-time equipment status

information• Fact-based timing of preventive

maintenance activities

Improved Performance Control• On-going monitoring of

measuring performance• Periodic asset status reports to

optimize processes

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Local contact: www.mt.com/contacts

Mettler-Toledo, LLC1900 Polaris ParkwayColumbus, OH 43240

Mettler-Toledo Hi-Speed5 Barr RoadIthaca, NY 14850

Mettler-Toledo Safeline6005 Benjamin RoadTampa, FL 33634

Mettler-Toledo CI-Vision2640 White Oak Circle, Unit AAurora, IL 60502

Mettler-Toledo, Inc.2915 Argentia Road, Unit 6Mississauga, Ontario L5N 8G6