News 9 Industrial Millions of Lozenges

News 9 Industrial Millions of Lozenges
Industrial Weighing and Measuring
Millions of Lozenges
With High Consistency
Under the well know brand name of Fishermen’s Friend, the U.K based company Lofthouse
of Fleetwood produces millions of lozenges daily, each containing a precise formulation
of ingredients. The unique taste is created in an efficient, safe and paperless dispensing
process under the control of the batch formulation system FormWeigh.Net.
In 1865 when Fleetwood was the centre of
the United Kingdom’s fishing industry, a
young pharmacist named James Lofthouse created an extremely strong liquid
containing menthol and eucalyptus. This
liquid helped relieve bronchial problems
experienced by fishermen in the freezing
off shore conditions. To make it easier to
transport in those harsh conditions,
James Lofthouse worked this liquid into
small lozenges. These lozenges were
much favoured by the local fishermen,
who soon began referring to the miracle
lozenges as their “Friends” and would
not leave shore without them.
Today around 5 billion Fisherman’s
Friend lozenges are consumed each year
in more than 100 countries. The complete product range includes 17 flavors.
The company manufactures its product
under the strict control of the Medicines
and Healthcare Products Regulatory
Agency (MHRA) and is certified to BRC
Global Food Safety Standard and ISO
Efficient raw material dispensing
Depending on the type of product, a different production process is required.
Lozenges are produced from a wet paste
which is then dried, whereas the sugar
free products are formed in a dry process
with blended powders. The process involves bulk raw materials and minor
amounts of separately added elements
such as flavours. These raw materials are
manually dispensed and controlled by
Tips & Tricks
Clear expectations
In 2009 Lofthouse was looking for an additional control for their dispensing areas. As Beverley Cliff, Production Technologist at Fisherman’s Friend explains,
“the company was looking for a batch
formulation system to improve its recipe
and material handling. The system needed to simplify the relevant process for the
operators and be validatable. A fast and
competent service support structure was
also a pre-requisite”
Fast mixing with large graphical display.
Only approved ingredients are accepted by the
Flexible production with mobile
weighing stations
They decided to use METTLER TOLEDO
as their formulation solution provider
and installed eight FormWeigh.Net
weighing stations, each equipped with an
ID30 PC terminal, an appropriate bench
scale and a printing unit. All stations are
mobile and mounted on portable frames.
This allows flexible production planning
and easy cleaning of the stations.
Paperless operation
In addition – the warehouse module of
FormWeigh.Net is used in the quality
control laboratory. After an accurate
quality control check, raw materials are
approved and labelled for use in production. Now, with the use of a barcode reader, the dispensing process has become a
paperless operation which is traceable
and efficient.
Increased visibility
FormWeigh.Net allows customer specific
configurations. Fisherman’s Friend included specific safety, process and HACCP
instructions into their formulations.
These simple and clear instructions have
resulted in an improved overall visibility
of the operations along with a higher
level of process safety. “The elimination
of risk from transcription errors and the
increased visibility of the dispensing process have been the main benefits from
introducing FormWeigh.Net” concluded
Beverley Cliff.
Mobile FormWeigh.Net weighing station.
Publisher / Production
Mettler-Toledo AG
MarCom Industrial
CH-8606 Nänikon
Subject to technical changes
© 02/2012 Mettler-Toledo AG
Printed in Switzerland
Newsletters 1/2012
Maximize Your
Profitability During
Weighing and formulation are
both critical steps in every production process. Formulation
errors can destroy entire batches
and result in the loss of expensive
raw materials. This may lead to
delays in the production process
and to increased costs.
Download our FormWeigh.Net®
ROI Calculator now and calculate
your optimization potential
during formulation, based on
your own products.
Error-free Order Packaging
of Light and Heavy Components
Schneider Electric Alombard produces very light weight as well as large, heavy electric
components. When packaging orders the challenge was to accurately count heavy and
small components at the same time. To avoid missing parts or overfilling, METTLER TOLEDO
suggested a reliable weighing system integrated into the conveyor system.
The France based company Alombard,
established in 1929 in Saint Pryvé Saint
Mesmin, has been part of the Schneider
electric group for around a decade.
Around 150 employees develop a whole
host of electrical equipment: electrical
connectors, flush-mounted boxes, and
devices for the connection of luminaries,
etc. The site is mainly responsible for
supplying the group’s logistics platform
which supplies its French customers. Given that almost 1200 parts are produced
per hour, product deliveries have to be
very precisely controlled.
Prompt order fulfillment
“We wanted a solution that would improve our packaging station for bags
of electrical components,” explains Marc
de Baudus, Methodology Engineer at
The Alombard site produces all kinds of electrical
components. Pictured here: flush-mounted boxes.
Alombard. “We have to be able to put
­together orders that involve very small
products, which in some cases weigh less
than 1.4 grams, as well as much larger
products where weight dispersion is a
­significant factor. Some bags were being
sent back to us because a tiny connector
was missing, a part without which the
electrical unit could not be assembled
properly,” he adds.
Integrated weighing solution
to avoid errors
Mr. de Baudus, who was already familiar
with METTLER TOLEDO because of its
counting scales, decided to contact his
regional commercial engineer, Manuella
Page, about the problem. “In view of the
low weight of some electrical components, the solution had to be able to
e­nsure an optimum level of precision.
Naturally, I proposed a KA15s platform
with a weighing capacity of 15 kg and
0.01g resolution combined with an
IND690 weighing terminal,” explains
Manuella. “I also suggested that we add
a barcode scanner to make it easier to
identify the bags and improve the traceability of operations”, she adds. The
weighing system, which was perfectly
­integrated into a belt conveyor, has been
providing operators with 100 % satisfaction for more than a year.
Thanks to this installation, only nonstandard bags need to be checked manually and this results in higher levels of
productivity. As a result, complaints
about incomplete bag deliveries, have
fallen dramatically.
IND690 weighing terminal connected with KA15s (15 kg x 0.01g)
weighing platform under the conveyor belt.
Reliable detection of missing items from bags
thanks to the, KA15s high precision ­weighing
Newsletters 1/2012
Weight Based Quality Control
High Throughput
Despite 100% Inspection
The manufacturing process for solar cells consists of a multitude of individual steps. A
weight check between each step ensures that only good wafers proceed to the next treatment. METTLER TOLEDO has the right products and the expertise to support machine
builders in successfully applying weight based quality control for solar cells.
The transformation process from a
block casted poly-crystalline silicon ingot to a solar cell consists of several individual steps. It starts with cutting and
shaping the ingots into wafers. Then the
wafers have to pass through several
etching, coating and printing processes
until it is a solar cell with the capability
to produce electricity. A strict quality
control check at the end of each treatment ensures only good wafers proceed
to the next production step.
Weight based quality control
Measuring the weight before and after
each production step is a fast and reliable
quality check. It allows for detecting de-
Newsletters 1/2012
viations in geometry, completeness and
density of the wafer before surface treatment starts. Then the weight difference is
used for checking results of etching,
coating and printing. It requires weigh
modules with repeatable precision between 10 mg and 0.1 mg.
One weigh module for all steps
METTLER TOLEDO’s high precision
weigh modules comply with the requirements. They can reliably detect deviations of less then 1 mg in a fraction of a
second. The WMS104C is the most often
used weigh module for quality control in
silicium based solar cell production. It
has a readability of 0.1 mg and the re-
peatability of 0.2 mg. The software applies filter algorithms to measure correct
and repeatable results in spite of vibrations from machines and draft from the
air conditioning system. An incorporated
calibration weight allows testing of correct function without need to remove the
hosting adapter for the wafer.
Fast communication to
keep the pace
The fast interface sends 92 filtered and
compensated weight values per second to
the control system. The transmitted data
can be converted to all common Fieldbus
Systems if required.
Simplified production process.
(Complementary quality control technologies to weighing are not shown).
Consultancy ensures successful
However, correct integration of weigh
modules is key for the successful use of
weighing technology in a solar wafer production process, since a number of challenging environmental effects have to be
taken into account. A close cooperation
during the design process between machine builders and the experts of METTLER
TOLEDO ensures achievement of optimum performance.
Reference weight of the
workpiece: w(wp) = A
Process Step adding or
subtracting material
of nominal weight plus tolerance
w(n) = e +/- Δe *
control. It can be applied to detect the
smallest deviations in assembling, molding, coating, etching and printing processes for many products. METTLER
TOLEDO has its own direct service and
sales force. Its experts are globally available for consulting customers in correct
integration of weigh modules into any
kind of quality control applications.
Ask METTLER TOLEDO how weight
based quality control can increase yield
in your production.
Weight based quality control is
not limited to solar cells
Manufacturing of solar cells is not the
only application for weight based quality
WMS104C Weigh Module
Post process weight of the
workpiece: w(wp)´= B
Readability: 0.1 mg
Capacity: 120 g
Settling time: 0.15 – 0.8 Sec.
Labyrinth in IP54 protects against
ingress of dust particles
Wash-Down option in IP66 for cleaning
with fluids
Workpiece is
|B – A – e| < Δe
Waste or
Adapt process
Next Process Step
* e may be a positive value in case of adding material (e.g. coating) or a negative number in case of
subtracting material (e.g. etching)
Newsletters 1/2012
Floor Scales
Hygienic Floor Scales
Work Horses for Wet & Harsh Environment
Fixed installation, liftable, or mobile solutions, hygienically designed floor scales provide
enormous flexibility in production planning and are built for fast and efficient cleaning
procedures. Depending on your application, different models may suit. The selection of the
appropriate floor scale enhances food safety and increases production performance.
Floor scales used in wet and harsh environments are confronted with heavy
loads, rough handling, waste material
and are regularly flooded with water during cleaning procedures. To ensure safe
food production, floor scales must be
built and installed according to sound
sanitary design principles, resist corrosive
environments, withstand cleaning detergents and allow simple and frequent
loading, weighing and unloading.
METTLER TOLEDO builds different types
of floor scales all specifically designed for
maintaining sanitation in wash down areas. The rugged design and stainless
steel construction enable these scales to
stand up to tough industrial environments. Their ingress protection starts
from IP65 for light wash down procedures and goes up to an IP69k protected
scale constructed to withstand high pressure cleaning.
Easy to lift.
Newsletters 1/2012
Several construction types simplify and
accelerate the regular cleaning procedure.
Ultra low profile floor scales
Low profile floor scales are built to safely
and quickly move loads on and off the
platform. This floor scale line combines
robust construction, easy-to-clean surfaces, and an exceptionally low profile
with short ramps. Two construction types
are available: one stand alone fixed model and a lift version. On the lift version, a
pair of built-in gas springs enables one
person to lift the scale manually with
minimal effort for cleaning the ground
underneath the scale.
frames. The M line focuses on providing
a multi interval weighing range with
three different resolutions in one scale.
These work horses can be used for many
applications when combined with a
broad range of accessories.
Highest accuracy on the floor
(K line)*
The K line stands for highest accuracy
with a maximum precision up to
6000e/7500e (single range). Built to
stand on the floor or in a pit, their capacity starts from 300 kg x 2 g up to 3000 kg
x 50 g. These provide a broad weighing
range for maximum flexibility.
Work horses – basic floor scales
Floor scales from METTLER TOLEDO are
used in dusty and humid areas. All types
can be placed on the floor, mounted on adjustable feet or installed into prepared pit
Easy to lift (PFA5../-7../-8..lift)*
Liftable floor scales can be installed on
top of a floor or in a pit and combine
stainless steel construction with complete
access for cleaning. METTLER TOLEDO
offers two types: manual or automatic
Low profile floor scales: For easy loading.
Just move it.
Best Practice
The Right Terminal for
Your Floor Scale
Floor scales for wet & harsh environment.
lifting. In case of a manual operation
only the top plate lifts exposing the inside of the scale and pit, whereas the automatic version is equipped with pneumatic cylinders that lift the entire scale.
At the flip of a switch, the automatic version tilts up 45°. For safety reasons this
version can be locked to prevent unauthorized personnel from operating the
system. Both types can be handled by a
single person, safely and easily.
mounting clamps in the floor are needed. They are parked where needed and
allow an optimal cleaning of the complete production floor.
Regardless of the environment or the required cleaning procedure, METTLER
TOLEDO offers a hygienic floor scale solution to support your safe and clean food
Terminals, optimized to your weighing application, are an essential part
of your floor scale system. The selection of the appropriate floor scale
terminal enhances food safety and
increases production performance.
Choose from a broad range of terminals from simple, easy-to-use terminal for straight weighing applications
to advanced instruments that can
accumulate data or communicate
with computers.
Terminals for wet & harsh:
*Name may vary depending on country
Move it (PUA5../PUA6.. mobile)*
Mobile floor scales can be moved simply
by lowering four wheels, no holes or
Wet & Harsh Floor Scales*
Load plate
Approved resolution
Platform Sizes
Weighing range
Ingress protection
K line
"Fix floor
"Stainless steel /
Mild steel "
Single Range"
"11.1"" x 13.8"" - 23.6"" x 31.5""
280mm x 350mm - 600mm x 800mm "
300kg – 3'000kg
IP67 / IP68
M line
"Fix floor
"Stainless steel /
Mild steel "
Multi Range"
"31.5""x 31.5"" - 60""x 68""
800mm x 800mm - 1500mm x 1500mm"
300kg - 3000kg
IP67 / IP68
"Fix floor
Stainless Steel
Single Range"
"39.4"" x 39.4"" - 78.75"" x 60""
1000mm x 100mm - 2000 x 1500mm"
"500lb – 10'000lb
300kg – 6'000kg"
IP64 - IP69k
"Fix floor
installation /
Stainless Steel
Single Range"
"24"" x 24"" - 48 x 60""
610 x 610mm x 1219 x 1524mm
Free sizes upon request"
"500lb – 10'000lb
300kg – 6'000kg"
Manual / automatic Liftable
Stainless Steel
Single Range"
"24"" x 24"" - 48 x 60""
610 x 610mm x 1219 x 1524mm
Free sizes upon request"
"500lb – 5'000lb
300kg – 3'000kg"
IP65, IP68, IP69k
Stainless Steel
Single Range"
"24""x 24"" -42""x 42"" - Free sizes
610 x 610mm x 1067 x 1067mm
Free sizes upon request"
"500lb – 5000lb
300kg – 3000kg"
*Name may vary depending on country
Newsletters 1/2012
Hazardous Area
Rapid Production Changes
A Formula for Success
The Swiss company Basler Lacke is a medium sized producer of specialty paints and
lacquers. Due to the nature and the competitiveness of their business, numerous weekly production changes are required and the quality of the small to medium sized batches is crucial. Most of the operations take place in a hazardous environment rated ATEX
Zone 1/21. Balances and Scales from METTLER TOLEDO are one key element of their
formula for success.
Quality & productivity
Basler Lacke production manager Mr.
Guler relies on high performance tools
and well trained operators. Considering
that a typical lacquer formulation would
contain on average 15 different substances in quantities ranging from a few
grams to a ton, scales offering the required process precision over a large
measuring range confer the ability to
work on a reduced number of scales and
to achieve higher productivity and consistent quality.
The quality and the productivity are significantly influenced by the measuring
range of the scale at the required process
precision. The larger the available measuring range, the fewer the instruments
required to cover the different weights to
be measured. In other words a complete
formulation could take place on 2 different scales whereas with less accurate
scales (offering a more reduced measuring range) the process would require 3 or
4 scales. Fewer scales lead clearly to simpler and faster operations, while at the
same time the rate of rejected or reworked batches decreases dramatically.
Continous process
Mobile scales are also considered an important production tool. For this purpose,
Newsletters 1/2012
Basler Lacke had opted, several years
ago, for a number of mobile scales using
the battery powered ID3sTx/PUMA
weighing terminal. These terminals offer
basic functionality and mobility in zones
classified Zone 1/21 and Div1. In the context of the introduction by METTLER
TOLEDO of the ID3sTx/PUMA successor
model, the battery powered IND560x,
Basler Lacke has conducted tests and
found out that the IND560x not only fulfills all the functions of its predecessor,
the ID3sTx/PUMA, but offers many more
functions that will open new possibilities
for the continuous process improvements
considered by Basler Lacke. It is this continuous process improvement attitude
that makes Basler Lacke a market leader.
METTLER TOLEDO pays particular attention to the practical feedback provided
by Mr. Guler and Basler Lacke in order to
continuously improve the functionality
and the construction of their products, to
satisfy the continuously evolving requirements of this industry.
A new terminal
The new IND560x brings uncompromised performance and productivity into
Division 1, Zone 1 and 21 classified areas. Intrinsically safe design, high speed
process control and internal active/active
I/O control set the benchmark for weigh-
Courtesy: Basler Lacke
ing in explosive areas. The IND560x is
designed for both process control and
manual weighing operations. Some key
features are:
• Easy to operate filling and batching
solution: the 560Fill application software allows prompt configuration of
sequences for filling, blending, dosing
and dispensing
• TraxDSP™ noise filtering system provides accurate measurements in unstable environments with noise and vibration.
• High reliability: calibration management monitors performance and alerts
operators of maintenance needs
For more information log onto:
Basler Lacke AG was founded in 1933
and is now with a headcount of 60 a
company of the Berlac Group, a globally active group specialized in the development and production of sophisticated solutions for surface coating and
plastic dyes for various branches and
applications. Berlac is an internationally established producer of high quality coatings specializing in the protection and finish of plastics, metal and
carbon, especially in the ski and
snowboard sectors as well as in the
automotive industry.
In Switzerland, Basler Lacke is the
leading producer of road marking
products. In order to be in business in
this challenging domain, they count
on innovation and flexibility. They offer
complete system solutions for all applications and cooperate tightly with
their customers and partners to generate tailor made solutions.
Discover the great versatility and mobility in
Zones1/21 Div.1 of the new IND560x weighing terminal
Find more about the concept of the Minimum
Weight that leads to a reduction of the measuring range of a measuring instrument on:
Newsletters 1/2012
Vehicle Scales
New Truck Scale
Cuts Downtime and Service Costs
Equipment that requires frequent, expensive maintenance is a bad investment. To reduce
excessive downtime and service costs, a Wisconsin foundry needed a new truck scale
that would stand up to harsh winters and heavy use. The solution was a durable METTLER
TOLEDO weighbridge with advanced load cell technology.
ThyssenKrupp Waupaca (TKW) is the
largest noncaptive iron foundry in the
world. A global producer of iron castings,
the company makes components for light
and heavy vehicles, construction, agriculture, HVAC, and other industrial and commercial applications. Its largest facility is
located in Waupaca, Wisconsin, USA, and
operates 24 hours a day, 7 days a week.
With a total of 700 employees, the site
melts more than 2,800 metric tons of
metal per day.
Keeping the operation running requires
trucking large amounts of material to and
from the facility. There are constant deliv-
eries of steel ingots, scrap steel, sand,
limestone, and other raw materials. Outbound trucks carry finished products and
waste materials such as refuse sand.
TKW uses a single truck scale to weigh inbound and outbound trucks. The scale is
essential for inventory and purchasing
management of the raw materials and for
ensuring that the trucks transporting materials comply with highway load limits.
As the facility’s only truck scale, it takes a
pounding. During its busiest period, the
scale handles 30 to 35 dump trucks within
a short time span. In total, TKW weighs
more than 3,500 trucks annually.
Service problems
Although TKW’s previous truck scale was
only 8 years old, it had become a source
of headaches. Brutal Wisconsin winters
caused the I-beam weighbridge to corrode badly. Snow and ice built up within
the scale structure, accelerating its deterioration. Additional problems resulted
from the scale’s analog load cells and from
rabbits chewing on the load cell cables.
The scale was not standing up to the
harsh environment. It experienced frequent breakdowns and required numerous expensive service calls. TKW was
spending nearly $13,000 annually on un-
The reliable operation of the METTLER TOLEDO truck scale has saved thousands of dollars in maintenance and repair costs each quarter.
Newsletters 1/2012
scheduled scale service, repairs, and recalibration. These costs were compounded by downtime spent waiting for parts to
be shipped and for service personnel to
Finding the right scale
The need for a better truck scale was evident. Superintendent of Maintenance Bill
Heschke and his team studied six proposals. Knowing the importance of the truck
scale, the purchasing team asked the
prospective suppliers for references. They
contacted aggregates operations and other facilities with truck scales that experienced a similarly heavy duty cycle.
The TKW team also thoroughly evaluated
the structural designs of the different
scales. “Its got to be built to last,” explained Heschke, “and cheapest is not
always best.” The high service costs of
the old scale taught TKW to read the fine
print regarding warranties. Some suppliers’ warranties would not cover a scale
experiencing the duty cycle that TKW requires.
to ensure accurate weighing at all temperatures. Their built-in predictive diagnostics system helps ensure the scale’s
reliable performance, and load cell cables with stainless steel sheathing resist
damage from rodents.
TKW’s final requirement was a smooth
installation process. The scale fit the existing foundation with limited modifications and was able to use existing accessories such as lights, horns, and displays.
Valley Scale and TKW began removing
the old scale on a Friday. By 5:00 p.m. the
following day, the METTLER TOLEDO
scale was installed and ready to weigh.
“We were very pleased with how it went
together,” said Heschke. “It was nice,
fast, and simple.”
After two years of use, the quality of the
METTLER TOLEDO truck scale continues
to pay off. The new scale has solved the
downtime problem and saved TKW thousands of dollars in service costs each
quarter. Valley Scale continues to provide
prompt, personal service to TKW, including an annual preventive maintenance
program for the new scale. Having a reliable truck scale helps keep TKW’s facility
operating efficiently, saving money and
providing peace of mind.
Innovative solutions
TKW accepted a proposal from Valley
Scale, Inc., an authorized METTLER
TOLEDO distributor that was providing
excellent service for other industrial
scales at the facility. It called for installing a METTLER TOLEDO steel deck
weighbridge with an orthotropic rib design, which is a stronger, more durable
alternative to I-beam designs. The combination of the high-quality weighbridge
and POWERCELL® PDX® load cells addressed many of the concerns about operation during the winter. POWERCELL
PDX load cells use digital compensation
Weighing the trucks that transport materials to and from the facility is essential for inventory and purchasing management.
Newsletters 1/2012
Use as a
Work Efficiency Resource
Webinars – Learn More With Little Time and Effort
Join a wide array of webinars to learn about various topics
from choosing the right technology to process optimization.
Our On Demand Webcasts are available
at your convenience, 24 hours a day.
Download Comprehensive Product Documentation
Industrial Weighing Catalog
Solutions for weighing and measuring needs in industrial production.
For more information
Mettler-Toledo AG
CH-8606 Greifensee
Tel. + 41 44 944 22 11
Fax + 41 44 944 30 60
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