SaintyCo offers the best check weigher solutions in China. We provide a cost-effective yet high-performance check weigher solutions for all industries. SaintyCo can provide excellent weighing solutions for quality control and measure & weight regulations.
Our checkweighers are widely used for different industries such as cosmetics, pharmaceuticals, poultry & seafood, meat, and more. We manufacture check weighers with robust performance and high weighing accuracy. It is also constructed with rugged machine design to ensure reliable operation on harsh production environments.
With SaintyCo reliable check weigher, overfilled or underfilled packages can be prevented. If you need the best check weigher for enhanced productivity, SaintyCo is a brand that you can trust.
SaintyCo Check Weigher
SaintyCo is a trusted check weigher manufacturer in China with many years of experience. We manufacture reliable quality check weighers to enhance your production process. Using this machine can provide a lot of benefits such as the following:
- Preventing underfilled and overfilled packages
- Minimizing waste
- Reducing rework time
- Provides completeness for packaging
- High capacity and high-speed
- High weighing accuracy
SaintyCo make sure that all our check weighers are compliant with international standards. We have certificates from GMP, FDA, and more. Rest assured that SaintyCo check weighers are certified by weight and measure regulations.
If you are looking for the best quality check weigher, SaintyCo can provide your needs. We offer reliable quality, competitive rates, excellent services, and professional after-sales support.
Send your inquiries today!
Check Weigher: The Ultimate FAQ Guide
This guide covers all information you are looking for about check weigher machine.
So, before investing in your next check weigher machine, read this guide.
- What Is A Check Weigher?
- How Does Static And Dynamic Check Weighers Compare?
- What Should You Consider When Selecting A Check Weigher?
- Why Is It Important To Use A Check Weigher For Your Production Line?
- What Are The Advantages Of A Check Weigher?
- What Are The Statistical Applications Of A Check Weigher?
- Where In The Production Line Should You Use A Check Weigher?
- What Items Or Products Will A Check Weigher Weigh?
- What Will Affect The Accuracy Of A Check Weigher?
- How Can You Protect Your Check Weigher From The Operating Surroundings?
- What Are Some Universal Tips When Handling Products For Your Check Weigher?
- How Will You Verify The Repeatability And Accuracy Of An In-Motion Check Weigher?
- How Will You Set Up Your Check Weigher To Ensure It Achieves Optimum Performance?
- How Will You Maintain The Scale Of A Check Weigher?
- How Does A Check Weigher Operate?
- Which Industries Will Use A Check Weigher?
- What Are The Parts Of A Check Weigher?
- What Are Some Environmental Protection Classifications Of A Check Weigher Controls And Enclosures?
- What Are Some Examples Of A Check Weigher Combination System?
- What Should You Consider When Selecting A Suitable Partner For Your Check Weigher?
- What FAT Procedures And Validation Documents Should A Check Weigher Have?
- What Are Some Benefits Of A Multi-Lane Check Weigher Solution?
- What Quality Standards Should A Check Weigher Comply With?
What Is A Check Weigher?
This is a system that will weigh products or items as they pass via a production line.
It will also classify the products by the preset weight zones and eject them out of the system by relying on their classification.
Besides, they will weigh all the items on the production line.
How Does Static And Dynamic Check Weighers Compare?
Here is how these two classifications of check weighers compare:
Static Check Weigher
This is also known as a manual check weigher.
Static check weighers measure the weight of products that are not moving.
Besides, you will use them to spot-check the weight of a small quantity of the total products.
These check weighers also determine the target weight for the dynamic check weighers.
Static check weighers assist in tare and net weight sample tests making sure you comply with industry-standard regulations.
static check weigher
Also, static check weighers can be found in rework stations of the dynamic check weighers.
Here, they will assist in ensuring the compliance of underweight products.
Dynamic Check Weigher
These are also known as in-motion check weighers.
Dynamic check weighers will automatically measure the weight of products as they move in the production line.
Dynamic check weigher
They have automated removal systems such as air jets or pneumatic pusher arms.
These removal systems always dispose of products that are off-weight.
What Should You Consider When Selecting A Check Weigher?
The factors worth considering include the following:
- Check weigher system
Here, you will select between static and dynamic check weighers for your production line.
- Product characteristics
Some check weighers are made to weight specific package types such as cans, cartons, cases, bags, etc.
Other products such as tall bottles may require unique check weigher units since they are unstable and top-heavy.
The common types of package you can weigh entail:
- Cans or bottles
- Cartons or boxes
- Environmental conditions
The surrounding environment will affect how efficient and precise the check weigher will be in the production line.
For this reason, understand your environmental condition as you select your next check weigher machine.
This will determine the check weigher suitable for you.
For instance, you need a check weigher with high ingress protection [IP] value if you will be operating it in an environment full of moisture and dust.
Some considerations here include:
- Checking if your working environment is extreme
- Confirm the air current at your production line
- Check if your operating systems are shielded from electrical noise
- Confirm the presence of moisture on the products that you are weighing
- Check if the check weigher will be shielded from water and dust
- Confirm the presence of corrosive elements in your operating area
- Software and connectivity
The check weigher you select impacts your revenue and productivity levels.
Some check weighers have suitable software and connections that ensure you attain the best technical compatibilities.
The software will enable you to attain accurate, swift, and in-depth analysis which helps you resolve problems along the production line.
- Combination systems
This entails equipping your check weigher with support equipment that enhances your production value.
For instance, you can include a metal detector within the food industry to ensure there are no foreign objects.
- Technology partner
Ensure your supplier has expertise when it comes to making high-quality check weighers.
- Regulations and certifications
Ensure the check weigher complies with all relevant certifications as per your industry.
Why Is It Important To Use A Check Weigher For Your Production Line?
A check weigher will ensure you attain the following:
- Brand security
By delivering quality products consistently, you will protect your business and profits.
This means that the total weight of the item matches what is written on the packaging labels.
No one would want to open a package only to find it does not meet the net weight indicated.
Different countries have specific regulations and standards that define the performance of check weighers.
- Plant efficiency
The check weigher ensures the following:
- Maximized efficiency
- Reduction of re-works
- Improved equipment effectiveness
- Consistent product throughput
- Minimize product give-away by ensuring weight management
- Weight control
The check weigher will weight, count, and reject items that do not meet the set requirements in your production line.
What Are The Advantages Of A Check Weigher?
Some of the benefits include:
- It ensures you meet all international, national, and regional standards
- It checks for any overweight or underweight items
- Measuring and reporting the efficiency within the production line
- Ensure compliance with the law regarding net content for pre-packaged items
- Classification of items in weight grades
- Check the performance by weighing before and after each process
- Confirm for missing parts in a package such as coupons, labels, products, lids, instructions, etc.
- Minimize item giveaways by employing check weigher totals in determining filler adjustments
- Ensure item compliance with clients, agencies, or associations
- Check the package mixes against the weight limitations to ensure the liquid to solid ratio lies within specific standards
What Are The Statistical Applications Of A Check Weigher?
- Analyzing production by classification or weight zones
- Get accurate fill weight data by using 5 or more zones
- Inspect the entire production efficiency via total weight and count
- Monitor the overall production rate efficiency [products per minute]
- Monitoring standard fluctuations to alert the operators or fillers of out of tolerance situations
- Make savings on labor control quality
- Keep the production printouts as setting records for the management and different regulatory agencies
- Linking packaging line information to upstream information and control units
- Analyzing the performance of filler heads in both multi-head and single fillers
- Printing production totals for batches, days, hours, etc.
- Offer statistical process control [SPC] for feedbacks, closed-loop controls, and adjustments of automated processes
- Use statistics to monitor the performance of long and short-term fillers
- Providing statistical process control [SPC] charts for process adjustments and manual feedback
- Interfacing with computer systems and PLCs to combine check weighers to the entire production process
Where In The Production Line Should You Use A Check Weigher?
Different companies will use the check weigher downstream in the production line before or after you package the products.
They will use the check weigher to ensure accurate fills.
Also, you can use it as counters after the cartoners making sure nothing is missing.
Furthermore, some industries use check weighers during pre-production to ensure you use the correct amount of ingredients.
What Items Or Products Will A Check Weigher Weigh?
A check weigher can weigh several products in the production line.
Besides, the products can have different weight ranges from grams to several kilograms.
Some items that a check weigher can weigh include the following:
- Blister packages or items like capsules and tablets
- Unprocessed or unwrapped food items before packaging
- Weighing products that have varying weights for billing or future references like delivery applications and warehouse
- Pre-packaged food items like trays, glasses, cans, wrapped items, etc.
- Confirming the density or volume of various mixtures like yogurt or bread
- Tubs of items, cartons, or boxes to ensure nothing is missing
- Counting weight-based content within bottles, packages, or bags like drink bottles, battery
carton on a check weigher
What Will Affect The Accuracy Of A Check Weigher?
Many conditions can affect how accurate the check weigher will be in the production line.
There are ways you can minimize these issues in your factory.
Some factors that will affect the accuracy of a check weigher include:
Some check weighers will better handle extreme environmental conditions than others.
For instance, some load cells cannot handle temperature fluctuations.
Dust and debris falling on the scale can offset the check weigher’s tare settings.
Vibrations from hoppers or presses can introduce unwanted signals or noise.
For this reason, ensure you isolate the check weigher from such interferences.
Air currents can affect the indications of the check weighers hence, avoid drafts within sensitive check weighers.
Besides, you can install a draft shield to help combat this issue.
Electrical noise like radio-frequencies or electro-static discharge can affect indications in a check weigher.
This originates from devices like cell phones, pagers, or other machines.
Also, a caustic environment can degrade parts of the c=scale and the load cell.
Take careful consideration of your cleaning operations and the products you are handling.
A suitable product to use in a check weigher will not shake when you pass it through.
Also, it needs to be tightly sealed in uniform packages.
For instance, unstable contents in a package cause the check weigher to take more time to attain accurate readings.
Furthermore, tall bottles are unstable because of their height to width ratio and will wobble as they move across the check weigher.
However, packages with a wide base are stable and easy to weigh.
Using guide rails can help minimize this effect on unstable items.
Also, reflective items can confuse with the photo eyes in the check weigher.
This can cause the check weigher to weigh the items late or not at all.
Besides, you can solve this issue by adjusting the orientation of the overhead lights and photo eyes.
Overloading the check weigher can happen due to incorrect spacing and timing as more than one item will be on the scale.
Solve this by properly spacing the items.
How Can You Protect Your Check Weigher From The Operating Surroundings?
The environment impacts the accuracy of your check weigher so it is important to protect it from the surroundings.
Some tips include the following:
- Purchase load cells whose strain gauges are well-sealed
- Shield the lines from occurring voltage spikes
- Ensure you keep the working area clean or shield it from falling debris
- If necessary, deionize the items
- Securely bolt the check weigher to a stable ground
- Ensure there is no physical contact between the check weigher and other mechanical units
- Make sure you shield the check weigher from radio-wave interference
- Ensure you ground all shields and parts contacting the scale
- Employ load cells suitable for the operating environments
- Ensure the check weigher and devices with strong vibrations are isolated
- Shield the scale or keep the check weigher from air currents or winds
- Train the staff using the check weigher on how to operate, maintain, the mechanics of the device
What Are Some Universal Tips When Handling Products For Your Check Weigher?
- Use guide rails before and after the check weigher to stabilize products; however, they should not touch the rails when weighing
- Employ automatic tare or re-zero when the main concern is item build-up
- Also, ensure you adequately space the items to ensure the check weigher re-zeros
- Wide items are more stable than tall and thin items as they have a larger base
- Rigid items are easy to weigh than free-flowing items
How Will You Verify The Repeatability And Accuracy Of An In-Motion Check Weigher?
Here are some steps that will assist in the verification process:
- Confirm the zero in static and in-motion check weighers
- Use a product that represents what you want to weigh using in-motion check weigher and measure its accurate weight using a static scale
- Power the in-motion check weigher and operate the belt at the speed you intend to use in the production line
- Place a test puck on in-feed belts allowing it to move to the live section of the check weigher and collect it after weighing
- Record the in-motion value of the check weigher
- Repeat steps 4 and 5 up to 32 times
- Verify that the zero value did not fluctuate and if changed, you will restart the entire process
- Finally, verify the weight of the test puck is static as when you began, and if it changed, you will repeat the whole process
How Will You Set Up Your Check Weigher To Ensure It Achieves Optimum Performance?
Here are some steps to make sure the checkweigher minimizes give-away while the item meets nutritional information and label weight:
- Mechanical alignment
Ensure the frame is firm and the conveyors are aligned to attain your specifications.
- Rejectors and photo eyes
Make sure the rejectors fire timely and photo eyes are in the correct position.
- Product transfer
Ensure products are stable and with the correct spacing to ensure the check weigher performs optimally throughout the production process.
- Chains or belts
Inspect these parts for wear and tear, and replace them when necessary to ensure you attain accurate weights.
Ensure you properly set the alarm for the triggers to activate as per the requirements.
- Product pitch
Make sure you have correct spacing between products so that only one product is on the check weigher per time.
- Grey zone validation
Run a grey zone check before the shifts or changeover of products by running an item at least 20 times to get valid outcomes.
Properly format the weighing reports to accurately represent the production process.
- Product setup
Enter the correct weight and size of products in the recipe and set correct specifications for over and under-weight cut points.
- Auto zero and calibrations
Properly calibrate the check weigher daily or when switching between different products.
Also, ensure proper spacing during weighing to allow adjustment of auto-zero routine.
How Will You Maintain The Scale Of A Check Weigher?
Use the following preventative maintenance practices:
- Lubricate all moving components
- Calibrate the check weigher to its highest accuracy level
- Conduct frequent inspections on bearings, belts, gear sprockets, chains, etc.
- Frequently inspect all load cells
- Ensure the machine is stable and balanced
- Inspect if the wires have any wear
- Reset every chip within the controller
- Properly adjust the eyes for accurate lock-out time
- Clean the machine to eliminate debris that will affect the accuracy
- Where applicable, reset the spacing and timing belts to ensure maximum product flow
How Does A Check Weigher Operate?
Check weighing is a process of comparing the weight of an item to the set limit.
The set limit is a pre-determined weight that you specify for every item or product.
For instance, if a product should weigh 1 kilogram, you need to check the weight of every bath to ensure they have the correct weight.
Also, you will adjust it accordingly depending on if it surpasses or falls short of the pre-set weight limit.
Features of a check weigher vary considerably depending on the model type.
However, the basic check weighers have indicators to highlight the weight reading.
It also has several components that ensure it operates efficiently.
Besides, you can place it anywhere in the production line.
For instance, you can have it in pre-production to ensure you use the correct amount of ingredients or post-production to ensure accurate product weight.
Which Industries Will Use A Check Weigher?
Several industries use a check weigher in their daily production processes.
These include the following:
- Food industries
- Cosmetic industries
- Automotive industries
- Pharmaceutical industries
- Chemical industries
- Beverages industries
- Transport and logistics industries
- Metal manufacture industries
- Fabrication industries
What Are The Parts Of A Check Weigher?
A check weigher has several components that ensure it continues to operate effectively.
Besides, since there are different types of check weighers, the parts will slightly differ depending on their features and applications.
Here are the main parts you will find in check weighers:
- Infeed section
This part is responsible for feeding the items to the check weigher.
- Weighing section
This is the part of the machine responsible for weighing the different items.
- Outfeed section
This part of the machine will handle the items after you weigh them by relaying them to the next production phase.
- User interface
This is the part where you will use to control the check weigher.
It comes with a programmable logic controller [PLC] and a human-machine interface [HMI] that allows you to set the weighting parameters.
- Conveyor belts
This part will relay the products to and from the weighing station.
Reject belts will sort unsuitable items from the others in your production line.
- Weight belt
This component sits on the load cell and will weigh your items.
- In-feed belt
This part will control the speed and the spacing between the items before you weigh them.
What Are Some Environmental Protection Classifications Of A Check Weigher Controls And Enclosures?
The classification will show the Ingress Protection [IP] of the check weigher.
The first and second values represent protection against solids and liquids respectively.
0 means there is no protection against any of these elements.
Besides, a higher IP value means the check weigher has ample protection from dust, debris, and moisture.
- IP 2X
- IP 30
- IP 54
- IP 65
- IP 66
- IP 67
- IP 69k
What Are Some Examples Of A Check Weigher Combination System?
For you to minimize the complexity, space, and integration of parts within a production line, you can specify the following combinations:
- Combined check weigher and metal detection units
- Combined check weigher and X-ray devices
- Combined check weigher and vision inspection devices
What Should You Consider When Selecting A Suitable Partner For Your Check Weigher?
Here are some factors worth considering when you are choosing your partner for the check weigher:
- Life support
They should offer relevant support throughout the operating lifespan of the check weigher.
Examples of life support elements include:
- Operational guidance
- Installation support
- Maintenance guidance
- Performance guidance
The partner should offer installation services to ensure the check weigher performs efficiently and is secure.
Also, the supplier should ensure the installation will adhere to:
- HACCP-based needs
- Compliance with the country’s guidelines
- Operates as it should
- Operators can properly and effectively use it
- Proper installation while referring to surrounding devices and rejecting units
- System commissioning
This means you should ensure the following before use:
- Ensure installation is as per the manufacturer’s recommendations
- The unit operates as it should
- Relevant training of staff
Suppliers can train personnel to ensure they understand how to operate the check weigher.
- Performance verification
Suppliers can assist users to ensure the check weigher operates consistently in its lifespan.
What FAT Procedures And Validation Documents Should A Check Weigher Have?
Validation and qualification should offer the following:
- Maintenance qualification
- Design qualification
- Operational qualification
- Performance qualification
- Installation qualification
- Pre-approved documents
What Are Some Benefits Of A Multi-Lane Check Weigher Solution?
- They meet filer capacity that is not met by single-lane check weigher
- Lower packages per minute [ppm] per lane will increase the accuracy
- They remove the need to shift from parallel to linear formats
- It allows you to minimize the linear space for handling package rates
multi lane check weigher
What Quality Standards Should A Check Weigher Comply With?
A check weigher should comply with a set of international and regional quality standards to ensure safety and efficiency.
Some of these quality standards include:
- Food and drug administration [FDA]
- Good manufacturing practices [GMP]
- CE mark of quality
- ISO certifications
For all your check weigher machines, contact SaintyCo now.