Reducing Waste with Smart Checkweighing Solutions

IN THE food manufacturing industry, waste reduction is vital for both economic efficiency and environmental sustainability. With modern innovations in checkweighing technology, manufacturers can reduce waste at every stage of production, from raw materials to finished products.

From Raw Materials to Finished Products

Traditionally, checkweighers have been essential for preventing underfilled or overfilled products, both of which can lead to waste. 

Modern checkweighing systems, however, have transformed this process by incorporating advanced load cell technology that allows for real-time weighing adjustments. These dynamic checkweighers, capable of processing hundreds of products per minute with exceptional accuracy, help see that every product meets its specified weight. This significantly reduces the chance of overfilling and material waste, allowing manufacturers to maintain production speed while adhering to stringent weight regulations.

In-motion Checkweighers are designed to handle a wide range of product types, from light items like snack bags to heavier products like canned goods, all without sacrificing accuracy. As products move down the line, advanced sensors adjust to each product’s unique weight requirements, facilitating optimal precision and compliance with legal metrology standards.

These systems are part of a broader shift towards Intelligent Weighing Automation, using real-time data and connectivity to drive automatic adjustments in the production process. By integrating checkweighers with upstream and downstream equipment, manufacturers can unlock smarter control over fill volumes, optimise line performance and significantly reduce material waste. This technology allows adjustments to happen continuously, in real time, without disrupting output, enabling higher accuracy and efficiency across the production line.

At the heart of this automation is Feedback Control, a smart communication loop between the checkweigher and the upstream filling machine. When the dynamic checkweigher detects a deviation from the target weight, it sends immediate data upstream, prompting the filler to automatically adjust its output. This intelligent response assists with consistent product weights without the need for manual intervention or production pauses. By reducing overfill, minimising giveaway and keeping production on track, Feedback Control demonstrates how intelligent systems can drive both compliance and cost savings while maintaining high throughput.

Reducing Waste through Preventive Maintenance

Once production is in full swing, the challenge shifts to maintaining operational efficiency. Unplanned downtime or equipment malfunctions can lead to production halts, resulting in wasted products that can no longer be sold. Preventive maintenance plays a key role in reducing this risk by identifying potential issues before they become critical, from basic cleaning routines to professional equipment inspections, worn part replacements and service recommendations.

By implementing a regular preventive maintenance schedule, manufacturers can keep checkweighers and inspection systems in optimal working condition. This helps to prevent downtime, avoid inaccurate readings and reduce the risk of spoilage or product loss due to unexpected shutdowns. 

Tackling Environmental Challenges with Vibration Compensation

Environmental challenges, such as vibrations from nearby machinery or unstable floors, can interfere with traditional checkweighing systems. In a typical manufacturing facility, conveyor systems, packaging machines and other high-speed equipment often create vibrations that skew weighing accuracy, leading to false rejects or incorrect weight measurements.

Modern checkweighing technology addresses this issue with vibration compensation mechanisms. These systems use high-resolution sensors and advanced algorithms to neutralise the effects of external vibrations, meaning that the weighing process remains precise even in dynamic production environments. 

By stabilising the weighing process, manufacturers can minimise the number of products that are incorrectly rejected due to vibrations. This reduces unnecessary waste caused by falsely rejected items while being sure that products are weighed accurately in any production setting.

Utilising Data for Continuous Improvement

The journey of waste reduction doesn’t stop once products are accurately weighed. Today’s Intelligent Checkweighers serve as a central part of manufacturers’ digital automation strategy, generating a wealth of data that can be used to further optimise processes. Each checkweigher continuously collects and stores performance data, allowing manufacturers to track trends, identify inefficiencies and adjust processes to further minimise waste.

For instance, by analysing product weight data over time, manufacturers can identify if certain products are consistently on the edge of acceptable weight limits. By making small adjustments to upstream processes, such as the filling or packaging stages, manufacturers can further reduce the likelihood of underfilled or overfilled products. This fine-tuning improves both material efficiency and compliance with weight regulations.

Data insights also provide a basis for long-term improvements. By reviewing historical performance metrics, manufacturers can predict future waste levels and adjust to optimise resource use, meaning that their operations remain as efficient as possible over time.

Frank Borrmann is market manager for checkweighing and vision at Mettler-Toledo Garvens

For more information: 

www.mt.com/cw-eguide-pr

Tel: +44 116 235 7070​