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Addressing the Common Problems of Checkweighers

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worker lining up meat products for weight checking

If your checkweigher malfunctions, your products may be compromised. Your food manufacturing facility relies on checkweighers for precise, accurate, and efficient product packaging, so one minor miscalibration could lead to a loss in profits, downtime, and customer satisfaction.

Whether you’re hoping to troubleshoot issues with your machinery or want to avoid the common problems of checkweighers, you’ve come to the right place. Below, we address the main issues you may face with your checkweigher and how you can resolve or prevent these malfunctions.

Common Mechanical Issues and How To Resolve Them

Checkweighers can experience numerous mechanical issues that impact performance. Whether you’re already experiencing problems or simply conducting a standard maintenance review, we recommend checking for the following concerns:

Component Wear and Tear

Various components can wear down over time, leading to mechanical malfunctions and failure in automatic systems. Components facing the highest risks of premature wear and tear include the following:

  • Load cells
  • Motors
  • Belts

You should conduct routine system evaluations and maintenance to check the above components for premature wear. Replacing or repairing worn-out parts early on can prevent sudden breakdowns while preserving your system’s health and longevity.

Conveyor Belt Problems

The conveyor belt can malfunction in numerous ways, impacting the system’s accuracy and overall performance. If the belt becomes misaligned, you may notice invalid weighing results. Frequent inspections and calibration of the belt can prevent this issue, but you also need to ensure that you’re positioning your products carefully in the center of the belt to reduce alignment problems.

High-speed conveyor belts can also struggle with product jams and blockages when large volumes of products must quickly move through the system. You can prevent blockages by implementing regular cleanings and re-alignments to ensure the belt operates at peak performance. You may also be able to install additional sensors or automatic shut-offs to prevent major blockages.

Calibration Issues

Checkweighers must be calibrated frequently to prevent inaccurate measurements. You also need to calibrate the machine correctly from the start. The initial calibration will impact the checkweigher’s performance moving forward, as this will determine the general weight category.

For example, if you calibrate the unit with 15 pounds, you will not be able to accurately weigh three-ounce products, as they will likely zero out. With your product weights in mind, you must set the zero scale, active zero tracking, and calibration correctly from the beginning.

Troubleshooting Electrical and Software Malfunctions

electronic engineer troubleshooting defects

Some of the most common problems of checkweighers can be traced back to electrical shortages and similar failures. If you’ve kept up with your maintenance requirements but your system continues to fail, you may need to address the following:

Power Supply Interruptions

Assuming your checkweigher runs on electricity, you may experience malfunctions from power supply interruptions. Faults within your electrical system, like issues with the wiring or power surges from poor infrastructure, can interrupt the checkweigher’s operation. We recommend checking for issues like blown chassis fuses, loose data cables, or frequent breaker trips.

If you have issues with power supply interruptions, you may need to upgrade the system’s grounding or power supply to ensure proper stability. Doing so can help you prevent outages.

Sensor Failures

The weight sensor should accurately pinpoint the product weight and location on the conveyor belt to determine which products are or aren’t qualified. The weight accuracy will fail if the sensor becomes loose, resulting in poor contact. The sensor may also fail entirely, leading to data jumps and inaccurate measurements.

In all cases, the sensor must be checked, tested, and secured regularly for optimal functioning.

Software Glitches and Bugs

Checkweighers operate based on the data fed to them from the software. Like any other tech, your software can glitch or develop bugs, ultimately impacting the checkweigher’s performance. Be sure to perform all necessary software updates to prevent glitches and contact your tech team at the first sign of failure.

Understanding How Environmental Factors Can Affect Checkweigher Performance

Changes in temperature may not seem like one of the common problems of checkweighers, but sudden environmental fluctuations can drastically impact system performance.

Temperature Variations

The load cell requires minimal environmental interference for accurate measurements. Extreme temperature fluctuations can impact the voltage inside the machinery as the wire resistance increases, ultimately impacting the validity of your results.

Your checkweigher should come with temperature recommendations from the manufacturer. For example, the IXL Standard Checkweighers from TDI Packsys offer accurate performance in temperatures ranging from 32 to 104 degrees Fahrenheit.

Humidity and Moisture Exposure

Humidity fluctuations can also impact performance. Exposure to extreme moisture conditions can cause the load cell output to vary from the number you see on the display. Your humidity should typically stay between 30% and 85%, but the ideal range will depend on your exact machine.

Avoiding Operational and User Errors

operator performing maintenance and repair on conveyor belt

One of the most common problems of checkweighers has nothing to do with the actual machinery. User error can lead to various issues from the initial setup to day-to-day operation.

Common Setup and Configuration Errors

You must set your checkweigher up correctly from the start to avoid errors down the line. If you set your system up for the wrong product type or fail to configure a few settings, you will experience numerous malfunctions. Here are a few common configuration errors that can occur during the setup process:

  • Setting the filter coefficient too small
  • Failing to set the zero scale
  • Selecting the incorrect product model
  • Configuring with inefficient power
  • Calibrating with the wrong weight

Take extra care to avoid making these mistakes. We recommend choosing a checkweigher that comes with installation support from the manufacturer to ensure that your system works correctly.

Deficiencies in Operator Training

Your operators must also be trained to use and manage the machine. They should be able to select the proper load cell for optimal accuracy, operate the software, perform basic maintenance tasks, troubleshoot malfunctions, and more. If the machine overrides, the team must adjust the products on the belt accordingly without allowing invalid products to pass through production.

All of these duties require careful knowledge of the machinery, software, and product. Your operators should receive regular training so you can prevent human error.

Difficulties With Product Handling

Your food products can also cause the checkweigher to malfunction. If you face these difficulties often, you may need to adjust your packaging or weighing mechanism to prevent further issues.

Products With Uneven Weight Distribution

The product should be in the center of the conveyor belt for accurate, precise readings. If your product weighs a lot more on one side than the other or the weight spreads unevenly across multiple sides, the checkweigher can malfunction.

Heavily lopsided products may not have the most accurate readings. If you notice a pattern here, you may need to adjust your sensors, recalibrate, or consider a different checkweigher.

Products Prone to Sticking or Blockages

Some products tend to cause blockages more frequently than others. If you notice issues with sticking and back-ups, you may need to adjust your packaging to prevent downtime and future mechanical concerns.

Preventative Maintenance and Ongoing Solutions for Smooth Checkweigher Performance Moving Forward

two workers wearing lab coats operating checkweigher

Now that we’ve gone through all of the most common problems of checkweighers, let’s discuss how you can avoid future malfunctions. Keeping your system running smoothly requires frequent upkeep and proper training. We recommend the following:

Conduct Regular Maintenance and Inspections

Routine maintenance keeps your system in great health for as long as possible so you can prevent inaccurate readings and other malfunctions. Here are some basic tasks we recommend performing during your standard maintenance:

  • Clean the system thoroughly
  • Lubricate all moving parts
  • Check all components for loose screws or fasteners
  • Inspect the load cell
  • Inspect timing belts
  • Inspect all wiring to check for loose connections
  • Reset chips
  • Test electrical grounding
  • Measure humidity and temperature points
  • Calibrate the machine using test weights

If you notice any major concerns, you should address them immediately.

Ensure Proper Operator Training

Your operators should be trained correctly from the start and moving forward for optimal system performance. Beyond the initial onboarding, you must follow up with continual training after any software updates. You should also regularly check in on the team to ensure everyone performs their roles correctly.

Here are some basic points to include in training:

  • Selecting the correct load cell
  • Operating the software
  • Performing maintenance
  • Troubleshooting common problems
  • Making conveyor belt adjustments
  • Responding to an override

Upgrade or Modernize Your Equipment

If your checkweigher frequently malfunctions even with routine upkeep and team training, it may be time to upgrade to more suitable, modern equipment. The latest models offer ultimate accuracy with high-speed stability for reduced errors, malfunctions, or headaches. At TDI Packsys, all our checkweighers come with easy assembly and cleaning instructions and highly sensitive load cells that do not require daily calibration.

Choose TDI Packsys for Hiccup-Free Operation

Avoid the common problems of checkweighers by upgrading your system today. Call TDI Packsys today at (877) 834-6750 to learn more about our advanced inspection machinery.

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