News Bakery & Snacks Industrial Weighing and Measuring 2 Our solutions and services for appli- cations along the value chain are designed to provide a quick return on investment. At goods-in/receiv- ing, efficient traceability and process visibility are important prerequisites which have to be realised for food safety. Scales are important identifi- cation points to collect traceability data and for clear labeling of semi- finished and finished products. In order to meet product quality, consist- ent taste and traceability, METTLER TOLEDO offers easy-to-operate stand- alone and fully networked formula- tion/recipe solutions. Monitoring, analysing and document- ing key quality parameters and mini- mising overfilling in manufacturing and packaging are achieved by our skilled Statistical Quality and Process Control (SQC/SPC) systems. To speed up production we offer bench/floor scales and terminals with fast display readout and ergonomic design. 100% control at a throughput of up to 400 weighings per minute, with high accuracy and without product flow interruption, can be achieved using our in-line checkweighers. We help to assure product safety and protect your brands. Contamination issues can be solved by our metal detection and X-ray inspection sys- tems to identify foreign bodies. Solutions from METTLER TOLDEO support product safety in hygienically sensitive areas and help to etablish efficient processes. Responding quickly to fast changing consumer demands, improving productivity and quality, increasing requirements for food safety and regulatory compliance are challenges faced by the bakery industry. With our weighing solutions we help to cope with these demands. Meet your business goals with smart weighing solutions BRC IFS ISO 22000
Transcript
NewsBakery &
SnacksIndustrial Weighing and Measuring
2
Our solutions and services for appli-cations along the value chain are designed to provide a quick return on investment. At goods-in/receiv-ing, efficient traceability and process visibility are important prerequisites which have to be realised for food safety. Scales are important identifi-cation points to collect traceability data and for clear labeling of semi-finished and finished products. In order to meet product quality, consist-ent taste and traceability, METTLER TOLEDO offers easy-to-operate stand-alone and fully networked formula-tion/recipe solutions.Monitoring, analysing and document-ing key quality parameters and mini-mising overfilling in manufacturing and packaging are achieved by our
skilled Statistical Quality and Process Control (SQC/SPC) systems. To speed up production we offer bench/floor scales and terminals with fast display readout and ergonomic design.100% control at a throughput of up to 400 weighings per minute, with high accuracy and without product flow interruption, can be achieved using our in-line checkweighers.We help to assure product safety and protect your brands. Contamination issues can be solved by our metal detection and X-ray inspection sys-tems to identify foreign bodies. Solutions from METTLER TOLDEO support product safety in hygienically sensitive areas and help to etablish efficient processes.
Responding quickly to fast changing consumer demands, improving productivity and quality, increasing requirements for food safety and regulatory compliance are challenges faced by the bakery industry. With our weighing solutions we help to cope with these demands.
Meet your business goalswith smart weighing solutions
Innovative flavours and product consistency are key to diffe-rentiate from competition. FormWeigh.Net® combines effi-cient, powerful formulation software with reliable weighing technology.
The perfect mixture is essential for product quality. First class bakery requires not only premium raw mate-rials but also total process control. To reproduce the same perfect quality every time, the line operator needs support from an ideal recipe system – FormWeigh.Net®. This system pro-vides important parameters such as materials, recipes, operator instruc-tions and raw-material information on a mouse-click. FormWeigh.Net® guides the operator securely and quickly through the daily formula-tion work. It provides all necessary information paperless in the central production area. Due to the simple and user-friendly screen layouts the
operators are able to work efficiently and accurately, even after a minimal training period.
Key customer benefitsn Accurate and reproducible qualityn Minimal waste material due to bad
batchesn Fast and accurate operation
through simple, user-friendly screen layouts
n Full traceability and regulatory compliance
n Prevention of loss through auto-matic correction of ingredients
n Easy integration into data man-agement systems (e.g. SAP)
The production process is document-ed, and every single work-step is registered in the database. Tracing production history is no longer a hassle for the quality or production manager. The required information can even be retrieved electronically in order to pass the data to a third party such as an auditor.
FormWeigh.NetMaster Station
BarcodeScanner
ID30 Operator Screen
LabelPrinter
Platform/Bench Scale
FloorScale
3METTLER TOLEDO Bakery & Snacks News
Fast, economic and ruggedCompact food scale
Organise your production process flexibly with the portable BPA224.
Our new BPA224 compact food scale is especially designed for the use in dry and light duty wet production and packaging applications. Simple weighing and portioning is performed in a fast and economic manner. The portable BPA224 – with its integrated rechargeable battery – supports you to organise your production proc-esses.
Fast Factsn Over/under checkweighingn Fast 7-segment LED display (stabi-
lisation time < 1s)n Portablen Internal rechargeable batteryn IP65 – easy to cleann Dual display
Key customer benefitsn Mobility due to built-in recharge-
able batteryn Fast weighing and portioningn Easy to operate
Moisture content of floura key quality parameter
The moisture content of raw materials and food products is key to high quality and effec-tive cost management. Innovative and successful companies such as Hiestand, the leading Swiss Gourmet Bakery, rely on top class measurement expertise to control the moisture content of the bread’s most important ingredient – flour.
Hiestand – a success story built on innovation and qualityIn 1987 the innovation breakthrough of Alfred Hiestand came with the idea of pre-proven dough. The resul-ting unique convenience level for Hiestand’s customers and the out-standing quality made the product highly acceptable, opening the way to new customer groups such as shop-in-shop bakeries, gastronomy or pet-rol stations. Rising from a small local bakery, sales have now reached almost CHF 500 million, covering Europe, Asia and Japan. Hiestand places a great emphasis on high food quality and safety, with their own laboratories. Their factories are certi-fied after IFS, BRC and HACCP.
HB43 Moisture Analyser for fast and precise quality testingEach day several trucks of flour are delivered to Hiestand production fa-cilities. The price paid is based on the weight of the shipment. Strict specifi-cations define the acceptance criteria of the flour’s moisture content. The deliveries are routinely tested in the QC labs prior to unloading the truck: a sample is drawn and then quickly analysed on the METTLER TOLEDO HB43 moisture analyser. This is an important batch release criteria and Mr. Linz, quality manager, is very satisfied with the performance of the HB43, used at multiple production sites. Halogen heating delivers quick, first time results, reducing the wait-
ing time for permission to unload the truck. Periodic on-site METTLER TOLEDO service calibrates and certi-fies the instruments in an “audit ready format”, while maximising instrument uptime and longevity.
Package qualityparameters
Product qualityparametersSensory test
Visual appearance (colour...)
Moisture
pH-value
Metal free?
Single piece weight
Net content OK?
Label OK?
Batch/lot ID OK?
Expiry date OK?
Undamaged?
Typical FreeWeigh.Net screens
Sealing OK?
4 METTLER TOLEDO Bakery & Snacks News
Stat
istic
al Q
ualit
y Co
ntro
l
Accurate monitoring of portions and final product weight is essential for controlling material use and fulfilling net content legislation.
Fulfill average weight legislationand reduce costs
METTLER TOLEDO solutions for statistical quality control combine ease of operation, quality data man-agement and analysis functionality. Sampling of fill quantities for liquid, pastry, powder or solid products immediately following filling allows precise adjustment through operator prompting or closed loop control to the filler from a dynamic check-
weigher. Unnecessary material losses are avoided and legal fill quantities and average weight regulations are met. Production processes conform with internal and external standards such as ISO and GMP. Our standalone compact solutions or networked systems provide statistical data, to understand, document and control profitability and quality.
Key customer benefitsn Save money by reducing overfillingn Avoid legal complaintsn Simple and informative online
status of filling process, allowing quick reaction
n Streamline internal QA procedures
Parameters Value Unit
Raw material costs 1.– EUR/kg
Packages produced 100’000 Units per day
Nominal fill quantity 100 g
Production days �50 Days per year
Production mean value 101 g
Overfill per package 1 g
Overfill per day 100 kg
Overfill per year �5’000 kg
Overfill losses 25’000.– EUR/year
Solutions that pay back!
? Handwrittentest report
Batch report with standardised data analysis
ID30 withFreeWeigh.Netmonitoring screen
Samplecheck
Garvenscheckweigher
Safelinemetal detector
5METTLER TOLEDO Bakery & Snacks News
Net weight control in useBahlsen St. Michel – one of the leading biscuit manufactu-rers of France – uses FreeWeigh.Net® to substantially re-duce overfilling costs.
At the Bahlsen St. Michel factory, in St.Michel-Chef-Chef, the annual pro-duction of 8000 tonnes of fine biscuits is surveyed by our Statistical Quality Control system FreeWeigh.Net®. At four sample check points finished prod-ucts are regularly weighed to assure the targeted net weight is met. If this is not the case the operator receives real-time information about the need to adjust the filling machine.Each of the sample checkpoints con-sists of a precision balance connected via Ethernet to the FreeWeigh.Net® system. The large full colour display of the XP4001 precision balance sup-ports fast and error free operation.The weight data sent to the system is
stored in the Microsoft SQL database and statistically analysed for further use by the quality manager.
Benefits for Bahlsen St. MichelMs Huvey, Quality Manager sum-marises: “FreeWeigh.Net® provides permanent online information and documentation about the actual fil-ling precision. This real-time trans-parency of the filling process allows immediate reaction and assures that unnecessary overfilling is avoided, which benefits us with real cost sa-vings.”
Compact solutions: SQC14/SQC16 – eliminate pencils and pocket calculators
Sample check your Bakery products on our entry level portable compact sys-tem for efficient net weight control:nFlexible for up to 300 articlesnStatistical analyses and graphical
representations
nLong-term and batch statisticsnKeyboard and barcode reader interfacenTrend analysis with alarms
PC-based/networked solutions: FreeWeigh.Net® – total quality control for quality products
Our expandable networked system ensures maximum networked protec-tion and connects to virtually any device for instant data collection and analysis of important process parameters:nPowerful quality assurance system
for all aspects of packaging and filling quality control
nStatistical quality data is evaluated online on the display screen or in freely definable reports
nDevices are linked by Ethernet/TCP/IP, data stored on MS SQL database
6 METTLER TOLEDO Bakery & Snacks News
Prod
uct I
nspe
ctio
n 100% control for fast baking processesCheckweighing/foreign body detectionGarvens S3 SHARK checkweigher/metal detector designed to meet HACCP guidelines.
Garvens S3 SHARK checkweigher/metal detector
Safeline T�0 X-ray inspection system
4www.mt.com/product-inspection
Today’s baking plant has to contend with the challenges of shorter produc-tion runs and more frequent change-overs, while continuing to ensure fresh product arrives in the store on time. The METTLER TOLEDO Product Inspection Division, comprising of the Garvens and Safeline brands, is the world's leading supplier of in-line checkweighing, metal detection and X-ray inspection systems. Machines are designed for ease of change-over, plus equipment reliability and sup-port services you can rely on.The baking industry places an intense focus on product safety, equipment reliability and durability, and cost containment. Garvens and Safeline have developed products and support-ing services to address each one of these requirements.
Product safetyAs an essential element of your HACCP program, our metal detection and X-ray inspection systems play a vital role in identifying solid contaminant sources in your process and removing contaminated product from the line.n Our inspection systems are built to
the highest sanitary design stand-ards, and are capable of withstand-ing the harshest washdown proce-dures in your raw dough areas.
n Automated product changeover features ensure quality inspection and rapid changeover on complex production lines producing multi-ple products.
n Safeline X-ray systems detect con-taminants such as glass and stone, as well as validate overall product integrity.
Equipment reliability and durabilityOur checkweighing, metal detection and X-ray inspection systems offer an unbeatable combination of real-world/real-product sensitivity, ease of use and reliability to deliver consist-ently high performance inspection in the toughest of production and sanitation environments.
Cost containmentWe know that inefficient filling, false rejects and downtime are not accept-able in the baking industry. You can count on our sales and engineering team to tailor a solution that you can rely on. We also provide a 24/7 hotline supported by experienced technicians and a worldwide service network unrivaled in the industry.
7METTLER TOLEDO Bakery & Snacks News
ServiceXXL Solution Customer Valuen Expert validation supportn Manufacturer developed
validation protocolsn Software update and
maintenance agreements
n Validated methods ensure �1 CFR Part 11 conformity
n Monitored user managementn Safe data mangement
n Industry specific equipment qualification packages
n Equipment re-qualificationn Factory trained and authorised
technicians
n Conformity with industry specific standardsn Avoidance of FDA warning letters and finesn Limited start up costs
n Calibration report ISO 170�5n Calibration certificate ISO 9000n Certification of measurement
uncertainty and MinWeigh
n Accuracy, reliability and traceability of measuring results
n Known measurement uncertaintyn Calculated minimum weight and
activated MinWeigh warning function
n Service agreementsn Installation and repairn Customer training and seminarsn Application and technical supportn Service centre
n Control of unexpected expensesn Optimised up-time and productivityn Documented proof of user trainingn Avoidance of contaminationn Service access from remote areas
Guaranteed servicekeep your business runningAvoid unnecessary downtime with our wide range of after sales service packages for your specific requirements.
With a range of innovative service solutions offering regulatory compli-ance, equipment calibration, train-ing, routine service and breakdown assistance, you can profit from sus-tained uptime, together with ongoing performance verification and long life of equipment. There is a range of contract options designed to comple-ment your existing quality systems. Each one offers its own unique set of benefits depending on the equipment and its application.
1. Statistical Quality Control/Statistical Process Control2. FormWeigh.Net® – Formulation/Recipe solution3. Process weighing4. Methods of moisture content determination
Share our knowledgeLearn from our specialists – our knowledge and experience are at your disposal in print or online.
Learn more about all of our solutions for the bakery and snacks industry at our website. You can find information on a wide range of topics to improve your processes, including case studies,
application stories, return-on invest-ment calculators, plus all the product information you need to make an informed decision.
