Suppose you run a potato chip packaging line. What would happen if you added 20% more chips to every bag without accounting for those costs? You’d likely be out of business in no time.
This is why installing a cutting-edge checkweigher on your production line is important. Checkweighers allow you to precisely measure the weight of products to ensure you’re filling every package with the correct amount.
Wondering how to choose the right checkweigher? With so many different types of checkweighers on the market, picking the best one can certainly be a “weighty” challenge. Here’s what to consider when shopping for a new checkweighing system for your business.
Factors To Consider When Choosing a Checkweigher
When selecting a checkweigher, don’t immediately jump on the model with all the latest bells and whistles. First, take the time to consider product features, accuracy requirements, your budget, and your desired production line speed.
Product Characteristics
If you’re shopping for a checkweigher, you’ve likely found several different kinds, each with its product handling characteristics. Here’s a brief rundown on different types of checkweighers and what they’re best used for.
- Static checkweighers: Static checkweighers are ideal for processing soft fruits, raw meats, and fish. They’re commonly used by quality assurance (QA) inspectors to verify that product weights are within tolerance limits.
- In-motion checkweighers: This type of checkweigher is typically found at the end of the production line. After packaging your goods, you can use an in-motion checkweigher to perform one last weight check.
- Multi-head checkweighers: These checkweighers are suitable for fully automated production lines. They employ 16 mini-weight head scoops to gather product up to the target weight. The scale then calculates how much each scoop weighs and deposits the correct product weight into the packaging.
Production Line Speed
In any business, time is money. You don’t have leeway to wait on a sluggish checkweigher that holds up your production line.
The best checkweighers are both highly accurate and incredibly speedy. If your production line demands ultra-fast processing, look for a checkweigher that can keep up with the pace. Some checkweighers have a throughput of less than half a second.
Accuracy Requirements
Accuracy is one of the most important factors to consider if you’re wondering how to choose the right checkweigher. An inaccurate checkweigher can cost you thousands in wasted product. On top of that, customers won’t be pleased if the product’s weight varies too much from one package to the next.
What’s your margin of error for weighing products? Are you not bothered if your packages have a slight weight variance, or do you require picture-perfect accuracy every time?
Budget
Before shopping for a checkweigher, consider how much you’re willing to spend. Systems can vary from small machines to more costly advanced models.
Additional Features To Consider
Here are a few more features to consider when looking for the right checkweigher.
Data Collection and Reporting Capabilities
The best checkweighers have advanced data collection and reporting features that allow you to keep tabs on product weights and discrepancies. You can send these reports to any device for easy viewing.
Ease of Use and Sanitation
Naturally, your checkweigher should be easy to use and come with detailed instructions. You should also look for a checkweigher that’s a snap to clean. Ease of sanitation is especially important if your business packages raw meat or other products that may contain harmful bacteria.
Durability and Reliability
You don’t want to buy a checkweigher only to have it break down in a couple of years. Look for a durable model and purchase your checkweigher from a brand with demonstrated reliability to ensure you get the most out of this purchase.
If your production line is in an environment with harsh conditions, look for a checkweigher that can withstand those conditions without breaking down. For example, low-humidity environments present the risk of electrical shocks, which can damage delicate equipment. In such an environment, you need a checkweigher that won’t buckle due to the lack of humidity.
Integration With Existing Systems
Production lines combine dozens, sometimes hundreds, of moving parts. It’s important to consider how well a checkweigher integrates with your existing systems before purchasing.
Compatibility With Your Production Line
Before buying a checkweigher, ask the manufacturer whether it will work properly with your existing production line setup. The checkweigher you choose should play nicely with other equipment, such as food metal detectors, x-ray inspection systems, color sorters, and automated packaging systems.
Data Transfer Capabilities
Many checkweighers come with USB data transfer capabilities. Simply connect your phone or another device via a USB cable to transfer data.
Top-of-the-line checkweighers have Wi-Fi reporting, which enables you to send data and reports to any Wi-Fi-enabled device. That means you won’t have to manually send reports to your devices, a cumbersome process that can cost your business a ton of time.
Regulatory Compliance
Some industries, such as meat packaging and pharmaceuticals, must meet strict regulatory requirements for weights and measurements. Failure to abide by those standards can be catastrophic, making reliable checkweighers a must.
Standards and Regulations for Checkweighing
Does your business need to comply with FDA or USDA reporting standards? If so, you’ll need to purchase a checkweigher that’s up to the job. For example, if your company produces drugs, each pill must always contain the same dose with no variance.
Compliance Requirements
The best checkweighers enable you to comply with the National Institute of Standards and Technology (NIST) net content laws for retailers, wholesalers, and processors. Not complying with these laws can result in warnings, fines, or legal action.
Choosing a Checkweigher Supplier
Now that you’ve learned how to choose the right checkweigher for your business, which supplier should you purchase from? Here’s how to pick a good one.
Experience and Reputation
A checkweigher is a big purchase, so you want to buy yours from a company that stands behind its products. Before buying, check out reviews of the company and its checkweighers. It’s usually easy to find these with a quick internet search.
It’s also wise to stick with a company that’s been around for over a few years. In doing so, you have the assurance that the company will be there for you if there’s a problem with your checkweigher.
Service and Support
Because a checkweigher is a large purchase, you should get the service and support to match. Choose a company that offers email and phone support at times that are convenient for your business. Support agents should be willing to answer questions before, during, and after the sale.
Training Options
Although modern checkweighers are fairly easy to use, you and your team might have questions about how yours works. The best checkweigher sellers offer on-site training to teach your employees how to use the new checkweigher. Trainers can explain:
- The proper way to use your checkweigher to minimize downtime
- How to use the data reporting feature
- The process for cleaning and disinfecting the checkweigher
- Maintenance and calibration requirements
Installation and Calibration
Purchasing a checkweigher is only the beginning. To get the most out of your machine, you must ensure it’s properly set up and calibrated.
Importance of Proper Installation
Correct installation of your checkweigher is crucial. If not correctly installed, your checkweigher might make errors when weighing products. This can range from irritating to unacceptable and downright dangerous.
Before installing, decide on the best place to put your checkweigher. Depending on the model, you may want to install it at the beginning, middle, or end of your production line.
Once you’ve installed the unit, you will have to adjust:
- Static calibration
- Dynamic calibration
- Product parameter settings
- Rejection settings
- Wi-Fi or USB data exporting
Regular Calibration Is Essential
Every now and then, checkweighers require calibration to ensure they’re weighing products properly. Your installer will probably calibrate the unit before you use it for the first time. After that, you or your employees will have to calibrate the machine regularly.
Calibration involves “teaching” the checkweigher what weight is acceptable and what is not. This ensures you don’t add too much or too little product to your packages.
Wondering How To Choose the Right Checkweigher? Reach Out to Us!
If you’re still unsure how to choose the right checkweigher for your business, TDI Packsys can help. We offer a variety of modern checkweighing systems, including IXL Standard, Multi-Sorting, and RWG High-Configuration checkweighers. We also offer food metal detectors and combination systems.
To learn more about our checkweighers, call TDI Packsys at (877) 834-6750.
