25 November 2024
Production weight control on high-speed lines
Optimizing production accuracy and efficiency: technologies and solutions for weight control in high-speed production lines
The role of checkweighers in high-speed lines
Checkweighers are automatic weighing systems that play a crucial role in production lines. These systems are designed to control and record the weight of each product in real time as it moves along the line, without interrupting the flow of production.
However, high-speed lines can present a number of significant challenges: the time available for weighing is extremely limited, which requires advanced machinery and technology capable of collecting data in fractions of a second, analyzing them and making immediate decisions, such as discarding a product out of specification or reporting it for further verification.
To optimize production, it is essential to choose weight sorters specifically designed for high speed operation and equipped with advanced sensors and fast processing algorithms, guaranteeing high reliability even in particularly demanding production conditions. Automation and precision must go hand in hand: systems must also be able to self-adjust, perform continuous calibrations and integrate the data collected with industrial automation and weighing management software.
Technologies used in weight control
Weight control in high-speed packaging and production lines is based on cutting-edge technologies that combine hardware and software to ensure accuracy, efficiency and continuity of operations. Weight sorters use advanced weighing control systems, designed to weigh products in motion without slowing down the line and are equipped with high sensitivity load cells, able to detect even the smallest weight changes in fractions of a second. Their ability to ensure real-time weight control is essential for high-speed applications where every millisecond is crucial to maintaining the production pace.
The sorters are also equipped with advanced algorithms that quickly analyze data collected by the load cells. These software not only calculate weight, but they can also perform pre-set tolerance checks, automatically discarding products that do not meet the specified parameters. The user interface is also crucial, designed to be intuitive and easily integrated with production management systems (MES) and Industry 4.0 infrastructures.
Thanks to this integration, weight control data can be stored and analyzed to gain valuable information about the production process. Some software may also include predictive diagnostics tools, which report anomalies or possible failures before they occur, minimizing downtime and ensuring maximum operational efficiency.
Modern technologies also make it possible to configure the checkweighers in a modular way, allowing companies to obtain tailor-made solutions and easily adapt the systems to the specific needs of their production line, both in terms of speed, of product type, thus increasing productivity and guaranteeing ever higher quality standards.
Advantages of weight control in high-speed lines
Weight control in a high-speed production line offers many advantages, helping to improve production efficiency, product quality and business competitiveness. The adoption of high speed checkweighers allows to successfully face the challenges of modern industrial lines, ensuring an optimal management of processes. Among the main advantages of using checkweighers are:
- reduction of waste and material losses: checkweighers detect in real time products that do not comply with the specified weight, allowing them to be identified and expelled from the line without interrupting the production flow. This reduces waste, avoiding packaging or distributing products that do not meet the standards. It also allows for a more efficient use of raw materials, improving the overall sustainability of production;
- product quality improvement: accurate weight control ensures that each unit meets the quality standards and specifications required by customers and industry regulations, which are key to strengthening a company’s reputation in the market;
- productivity optimization: thanks to the ability to operate at high speeds without compromising weighing accuracy, the checkweighers allow you to maintain a fast and constant production rate. The ability to automatically monitor and correct any faults reduces downtime and line slowdowns, significantly increasing operational efficiency;
- compliance with regulations: the laws governing weight control in products, especially in the food, pharmaceutical and cosmetic sectors, are very strict. Checkweighers help to ensure that products comply with local and international regulations, avoiding possible fines, product recalls and damage to the company image;
- reduction of operating costs: more precise management of materials and the reduction of waste result in considerable economic savings for the company. To calculate how much you can save, simply multiply the quantity of product that would have been discarded by the cost of the product. In addition, automation of the weight control process reduces the need for manual intervention, lowering labor and supervision costs;
- real-time feedback: as we have seen, advanced weight control systems are equipped with software that can analyze data in real time and provide detailed reports on line performance. The possibility of immediate feedback allows to identify and solve problems quickly, continuously improving production processes;
- integration with management systems and IoT: checkweighers can be integrated with production management platforms and IoT technologies, offering remote supervision and centralized data collection. This intelligent approach allows for better product traceability and greater transparency throughout the entire production chain.
Nemesis high speed checkweighers: innovative solutions for weighing products on high speed production lines
Nemesis offers innovative and highly customizable solutions for weight control in very high speed production lines, meeting the needs of a wide range of industrial applications, from food to pharmaceuticals. Nemesis checkweighers are distinguished by their ability to adapt perfectly even to the most complex and articulated production contexts, integrating seamlessly with existing lines and guaranteeing top-level performance. Thanks to the flexibility in design, each machine is custom made to meet the specific needs of the customer, including customizations related to the dimensions of the belts, load capacity, ejection options and operating speed.
In particular, the R-Series conveyor belt scales are equipped with a special system of chain belts for handling cylindrical and tall products (such as cans, jars and tetrabrik), also thanks to the guiding rails that stabilize the products during all phases of feeding, weighing, exit and transport. Thanks to their specific characteristics and the IP 69K protection rating, these machines are particularly suitable for working in harsh environments, even in the presence of chemicals or corrosive substances.
A concrete example of the use of Nemesis checkweighers in high-speed lines is the case of D. Nomikos, the largest Greek tomato processing company, who required a system for weighing tomato sauce cans capable of operating at 600 pieces per minute. To meet the customer’s needs, Nemesis has designed and built a tailor-made solution, consisting of an R-series checkweigher with chain belts to ensure safe handling of the cans, a high speed ejection system for over-weight products and a robust conveyor line, always on chain belts. The system, equipped with the innovative EasyWeigh® software, allowed the company to achieve a scale interval of 2 grams without sacrificing production speed.
Thanks to their reliability, precision and flexibility, Nemesis checkweighers are therefore ideal solutions for companies with high production volumes and operating in harsh production environments. The ability to adapt to different needs, combined with the continuous support of the Nemesis team, makes them indispensable tools to increase productivity and guarantee high standards of quality and safety.
For more information about our checkweighers or to request a personal consultation, contact us!
