Dynamic checkweighers for maximum efficiency and safety
Dynamic checkweighers are indispensable in industry when it comes to ensuring product weight and completeness as well as controlling processes. This applies in particular to the food, pharmaceutical, chemical and cosmetics industries. As a leading provider of state-of-the-art technologies, we understand the high demands of our global customers in terms of durability, precision, throughput, hygienic design and compliance with legal requirements and industry standards.
We offer a comprehensive range of dynamic checkweighers that can be precisely customised to individual requirements. For particularly demanding applications, we develop customised solutions that ensure maximum accuracy and speed in product inspection. Thanks to our technologies, production processes can be monitored and controlled in real time, ensuring maximum efficiency and product quality.
All checkweighers are approved for use in legal metrology for FPV checks and are MID-compliant (in accordance with OIML R51). Our checkweigher portfolio also covers all relevant weight classes and offers solutions for a wide range of applications, from light to heavy products
In-line checkweighers
With the Essentus®, Synus®, Flexus® and EWK models, we offer a complete product portfolio in the in-line segment, which covers a product throughput of up to 600 items per minute. Each of the checkweighers is characterised by a stable and robust mechanical design to guarantee precise and reproducible weighing results even at maximum speed.
Flexus® checkweigher
The Flexus® checkweigher combines hygienic design with flexibility and maximum performance. It was developed in accordance with the strict hygienic design guidelines for production packaged food products. A wide range of configuration options covers practically every requirement. Further product features:
- High-resolution EMF load cell technology combines maximum throughput with the highest precision
- Optimised standard configurations for versatile application options
- Can be combined with Mitus® and Vistus® metal detection technology
- Optionally with stainless steel conveyor for use in harsh environments
- Optionally available in a verified version
Checkweigher Synus®
With its modular and configurable design, Synus® can cover numerous applications - including those where calibration is mandatory. Further product features:
- High-resolution EMF load cell technology combines high throughput with maximum precision
- Maximum throughput 250 pieces/minute
- Optimised standard configurations for a wide range of applications
- Can be combined with Mitus® and Vistus® metal detection technology, even after initial installation
- Adjustable height of the conveyor belt to adapt to changing situations due to the balcony design
- Optionally available in a verified version
Checkweigher EWK
The EWK is a precise checkweigher based on our proven EMK load cell technology. Its product features:
- Weighing range 30 or 60 kg
- High accuracy combined with high throughput
- Optionally in verified version
Essentus® L checkweigher
Essentus® is the entry-level version for numerous weighing applications, completeness checks and the optimisation of filling processes. The checkweigher is exceptionally user-friendly, is customised to suit and therefore enables low acquisition costs. Customers have the choice between
- Essentus® efficiency electronics for pure classification and single weight output
- Essentus® performance electronics for extended checkweigher functions such as
- Automatic teach-in function for easy commissioning and setting of weighing parameters without detailed knowledge of the device
- Wide range of options
- Can be combined with Vistus® metal detection technology
- Automatic speed control
- Extended analyses
- For product weights up to 6 kg
- Optionally with stainless steel conveyor for use in harsh environments
- Optionally available in a calibratable version
What customers can expect when buying a dynamic checkweigher from Minebea Intec:
- Intuitive user interface with Blue HMI*: Enables users to configure or adjust products quickly and error-free, as well as to gain an in-depth insight into the production process and derive optimisations from it. No special training or prior knowledge is required, ensuring maximum availability and productivity.
- Wide range of interfaces: The wide range of available interfaces enables seamless integration into existing data networks.
- Networking with the SPC@Enterprise software for efficient, centralised data and statistics management. Benefit from optimised workflows and fast, historical reporting.
- Highest weighing accuracy: Guarantees fulfilment of legal requirements and avoids reject errors, which improves the efficiency of your production with optional calibration capability
- German quality and decades of experience: Our checkweighers are characterised by reliable operation and a long service life, making them a safe investment.
- Optional trend control function: This function optimises filling processes and reduces cost-intensive overfilling, which increases efficiency and cost-effectiveness.
*Blue HMI is not available for the checkweigher Essentus
End-of-line checkweighers
Minebea Intec offers a wide range of high-performance checkweighers for a wide range of applications, including completeness checks and weighing of large bags and containers in the food industry segments,Building materials and chemical products.
Checkweigher EWK
The EWK is a precise checkweigher based on our proven EMK load cell technology. Its product features:
- Weighing range 30 or 60 kg
- High accuracy combined with high throughput
- Optionally in calibratable version
Checkweigher Essentus® H
The Essentus® checkweigher in the H version is a highly economical solution for checking weights at the end of the production line.
- Weighing range up to 60 kg
- Easy to operate
- Robust conveyor technology and design
- Many belt lengths and widths
- Available as Efficiency version for pure classification and individual weight output and as Performance version for extended checkweigher functions
Multi-lane checkweighers for maximum throughput in the smallest of spaces
We offer customised adaptations for checkweighers because we understand the many different requirements and environmental conditions of our customers. Our experienced design engineers are ready to carry out a wide range of customisations, from small modifications to larger projects, such as high-speed functions or multi-lane checkweighers.
Multi-track systems are extremely space-saving and offer decisive price and throughput advantages:
- Simultaneous checkweighing in 2 to 6 lanes
- Management of all tracks via a central, user-friendly user interface
- Throughput up to 600 pieces/minute
- Track-related control and rejection
Even better with the Blue HMI user interface for checkweighers
Regardless of whether a new product needs to be taught in, line parameters fine-tuned or a batch report created - the Blue HMI user interface of the new checkweigher promises speed and simplicity. Time-consuming tasks and extensive training are a thing of the past. With the new Blue HMI, we are now providing our customers with an optimised control system.
For safer and more efficient production
An insight into the production process is guaranteed by the checkweigher. The Blue HMI displays the efficiency (OEE) of your system and other statistics based on on current weighing results. For audits, it offers support with several integrated logging functions. Our aim is to ensure that you are optimally prepared at all times and the regulations are complied with.
Always keep an eye on your weight
The Blue HMI is a web-based, cross-platform user interface with multi-user security. This means you always have an overview of which steps have been carried out by authorised users on the network can be executed on the checkweigher, while the data is stored locally and securely on the checkweigher. You can therefore conveniently view configurations, weighing statistics and efficiency logs. You also have the possibility to connect to SPC@Enterprise from Minebea Intec, OPC UA clients, ProfiNET and Ethernet/IP gateways.
Product videos
Checkweigher Essentus®
Essentus® is the ideal economic solution for numerous weighing applications, completeness checks and filling process optimisation. The dynamic checkweigher is extremely user-friendly, is selected according to needs and thus reduces procurement costs. Customers have the choice between Version L for product weights of up to 6 kg, version H for product weights of up to 60 kg, Essentus efficiency for pure classification and individual weight output as well as Essentus performance for extended checkweigher functions. Simply configure your Essentus checkweigher according to your requirements.
Checkweigher Flexus®
Flexus® is your solution for ensuring optimum product quality, regardless of whether you want to check the weight and/or integrity of your product or optimise your filling processes. The high-resolution EMFC load cell technology and a tailored design guarantee precise weighing results and a high throughput of up to 600 pieces per minute.
Flexus® is easy to integrate into your production environment. Changes to line configurations and quick transitions between products are handled quickly and easily. Specifically designed for the food industry, Flexus enables easy inspection, as well as simple and safe cleaning.
Trend Control for Checkweighers
Calculate your savings potential for overfilling and rejects in production
Best Practices
Dynamic checkweighers for an efficient process
The confectionery manufacturer Sulá GmbH in Metelen, Germany, uses the Synus® dynamic checkweigher to sort out packs outside the legal tolerances. This is connected to the SPC@Enterprise quality management software, which is used for centralised data maintenance and evaluation.
Dynamic fill level control
The Chinese biopharmaceutical company Sinovac Biotech Ltd. uses our Synus checkweighers for maximum reliability in its vaccine production. The checkweigher checks whether the package is complete.
High-speed checkweighing
For the dynamic checkweighing of its long, narrow packs, a leading global food manufacturer was looking for a reliable and versatile checkweigher that could guarantee high quantities. We provided them with a customised solution.
FAQ Checkweighers
How does a checkweigher work?
In principle, a distinction must be made between dynamic and static checkweighers: Static scales are table or floor scales on which products have to be placed manually and the scale determines the period of time when it has reached a weight estimation. This leads to highly accurate weighing results, however, this procedure can only be carried out on a random basis.
A typical dynamic checkweigher usually consists of a system of three conveyor belts arranged in a row, whereby the important infeed belt takes over the task of taking the product from the customer's conveyor belt, correctly separating it by product acceleration and transferring it as perfectly as possible to the following belt, the weighing belt. Minebea Intec offers strain gauge technology as well as high-precision and extremely fast EMF (electromagnetic force compensation) technology. The outfeed or discharge conveyor removes the product from the weigh belt and using any of our suplimentry products such as reject systems seperates the products however the customer requires, normally incorrect weights are removed from the production line alowing good products to go to the next processing stage. This can all be recorded either locally at the checkweigher or using suitable software tools such as SPC@Enterprise. Dynamic checkweighers (with or without integrated metal detectors) provide an enormous amount of important data about the actual performance (and thus efficiency) of production lines due to their complete recording of all measurement results. In order to be able to evaluate and assess this data more easily, Minebea-Intec offers a variety of data interfaces, as well as ready-to-use, bi-directionally communicating evaluation tools such as SPC@Enterprise.
What are typical applications for dynamic checkweighers?
Compliance with the pre-packaging regulation
Automatic checkweighers have been in use since about 1965. Many applications of these scales are subject to national legislation regarding minimum and average weights Manufacturers of pre-packaged products with a uniform nominal weight displayed (and thus sold) to the end user must ensure that the products put into circulation do not fall below certain nominal values. Compliance with this rule is ultimately the responsibility of the manufacturers of such pre-packaging. In order to comply with this prepackage regulation, many countries in the world additionally require an (independent) periodic inspection (in Europe "verification") of the measuring equipment (checkweighers) used in these production facilities. In the EU, Russia and Japan, in addition to initial placing on the market and periodic on-site inspections (verification, recalibration), a type approval of these measuring instruments (checkweighers) is required by law in these regions, which proves the measuring accuracy of the instruments used based on previous tests by nationally accredited institutes (e.g. PTB, NMI etc.). (EU:MID regulation). The type approval is a prerequisite for putting a checkweigher into operation or recalibrating it on site under real production conditions.
Completeness check
Products to be weighed can contain liquids, powders but also solid components, which can have an infinite number of different weight values. However, certain products contain a finite nominal number of components whose individual weights are more or less known. Such products can therefore (theoretically) only assume a finite number of weight values. In particular, one might think of only one or a few missing component(s) that make a product (final packaging) incomplete. The task of a dynamic checkweigher is to check products for completeness and to eject incomplete products from the production process with sufficient measurement reliability. Completeness control is used both for individual packaging and for end-of-line packaging such as cartons.
Quality Control
A further task is the purely internal quality control, where a deviation of the target weight (both over- and underweight) indicates faulty production, e.g. the weight control of a casting, from the weight of which it can be seen whether there is, for example, a shrinkage (air bubble inside), which requires the rejection of the controlled part.
Classification
In the applications mentioned above, classification is also used, but only in the classification of good and bad, and certain weight values are therefore accepted or rejected. Another application, however, is classification in the sense of class assignment. Often several successive discharge mechanisms are used to feed products of different weight classes into different further lanes or collection containers, which then only contain products with weights within the previously defined weight ranges. For example, a collection container no. 1 contains products with weights between 100g and 120g, collection container no. 2 contains only products with weights between 120g and 140g, etc.
Optimization of the filling and dosing processes (trend controller)
Another task of a checkweigher can be the active control of a filling process. The so-called trend controller of a checkweigher has the task of influencing the filling, portioning or slicing machines upstream of the checkweigher by means of corresponding control signals in such a way that the weight value defined as the target weight is reached and kept as constant as possible. For this purpose the weighing results are evaluated accordingly. As a result of the evaluation, a control signal (manipulated variable) is sent, which is used to adjust the filling unit. The control parameters entered determine the type of evaluation and the control characteristics. These must be adapted to the characteristics of the filling unit to be controlled. The parameter "target value" defines the desired target weight to be maintained.
Fields of application of checkweighers in various industrial sectors
In order to give a better impression of what checkweighers are used for, please find below examples of the tasks performed by the products in the various industrial sectors.
FPV control (e.g. according to international OIML R 87 recommendations)
- Food: ready meals, containers of baking mixes, chewing gum packs, confectionery
- Building materials industry: cement, lime, plaster, mortar
Completeness check (check number per packaging unit)
- Plastic: toy containers, injection moulded parts
- Metalworking: screw assortments, ball bearings, DIY articles, furniture and construction fittings
- Food: ice cream, confectionery, bakery products, frozen food
- Cosmetics: Hygiene products
- Publishers: Books
- Pharma: Cartons with blister pack and package insert
Quality control (testing of quality characteristics by weight)
- Plastic: wall thickness, air bubbles
- Metal processing: Check castings for blowholes, check punched and moulded parts
- Injection molded parts: completeness, air inclusions
- Baked goods: Dough pieces
- Food: Ready-to-eat meals, containers of baking mixes, chewing gum packs, confectionery and other
- Plastic container: stability, wall thickness
Classification (distribution in weight classes)
- Food: Non-balanced products such as fruit, vegetables, meat, fish
- Natural products: Plant cuttings, flower bulbs
Trend controller
- Food: dairy products, ice cream, confectionery, bakery products, spices, baking powder, pasta
- Building materials industry: cement, lime, plaster, mortar
Peripherals (accessories) for checkweighers
A variety of application-specific peripherals are available, such as suitable reject systems. As part of our checkweigher solutions we offer a wide range of high-speed reject systems - for reliable and effective rejection of products with weight deviations beyond the defined tolerance. The rejection systems include pusher, blower, swivel arms and multisegment rejection. In addition, there is a wide range of sorting devices, (monitoring) sensors, hoods, collection containers, special software and interfaces, through which our sales engineers can provide advice.
Which features of checkweighers are important?
Dynamic checkweighers must meet both current and future industry requirements to guarantee a safe production chain. Product changes are not uncommon, which requires a high degree of flexibility of the scales. Minebea Intec offers a wide variety of dynamic checkweighers, all of which can be configured to individual requirements. The weighing belt can also be dismantled later without tools to allow adjustments and minimize downtime.
Important features are high measuring precision and throughput. For example, the Flexus® in-line checkweigher can achieve a product throughput of up to 600 pieces per minute. This product is also available as a high-speed version, offering extreme process speeds of up to 2.6 m/s. The necessary precision is ensured by the use of state-of-the-art electromagnetic force compensation (EMFC) technology. For very special applications, the company provides tailor-made solutions. For example, the frame construction of Flexus® allows the assembly of many different additional modules to offer suitable solutions for special applications. Thanks to its modular and configurable design, the Synus modular checkweigher covers a wide range of applications, including those requiring legal metrology. It is possible to integrate the Vistus metal detection technology even after the initial installation. The checkweigher can thus be extended to a combination instrument. For moderate requirements and limited budgets: the models in the Essentus® range are tailored to the needs of individual user groups: The in-line checkweigher is available in two versions: The Essentus efficiency offers basic features, while the Essentus performance offers advanced functions. Both devices are available for different weight classes: Firstly as an L version, which is suitable for light products up to 6 kilos - and then as an H version, which can weigh heavy products of up to 60 kilos.
Hygienic design also plays an important role when using a checkweigher for the food and pharma industry: The guidelines of hygienic design form the basis for open processes in food production. In food production, product contamination by microorganisms such as bacteria or fungi is an omnipresent risk. Hygienic solutions means the hygienic design of parts, components and production facilities to guarantee complete cleanability. The multi-track systems from Minebea Intec are suitable for systems with several tracks: These can carry out check weighing in up to six tracks simultaneously and can be managed simultaneously. The tracks can be individually controlled. Depending on the product, different variants are available, such as pushers, which push the product sideways off the belt, blowers, which remove the product from the belt using compressed air, swivel arms, which lift defective products off the belt, or multi-segment separators, which minimize material loss through a multi-part separation system.
Another possibility is the use of combination devices, like the Flexus® Combi or the Cosynus, which are a combination of checkweigher and metal detector. In addition to checkweigher functionality, these offer reliable detection of foreign objects through the integrated Vistus metal detection technology. This solution considerably reduces the space required on the line and optimizes user control. Both the checkweigher and the metal detector are only controlled via a common user interface. Some companies fit 3rd party metal detection devices or checkweighers to their own units. Minebea Intec is one of the few companies in the world that design and build checkweighers and metal detectors in one factory.
If you have further questions on this topic or are looking for an individual solution for your application, please use the contact form below or send an e-mail to our sales team.
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