Latest Statistical Quality Control System In Use at Nestlé ... · PDF fileLatest...

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BeveragesIndustrial Weighing & Product Inspection

Latest Statistical Quality Control SystemIn Use at Nestlé TurkeyNestlé – one of the oldest foreign investments in Turkey – entered the

Turkish market in 1875, only 8 years after its foundation. The Turkish

METTLER TOLEDO distributor BAYKON has served Nestlé for many years

with top-class weighing technology and Statistical Quality Control

(SQC) systems.

A century in Turkey100 years ago, in 1909 Nestlé opened its first sales office in Istanbul introducing Nestlé’s baby food, concentrated milk and chocolate products to Turkish consumers. With strong confidence in the Turkish market, Nestlé opened the first chocolate factory in Turkey in 1927.

Nestlé continued to be the first company to introduce new products into Turkey. In 1968 Turkish consumers were introduced to chocolate spread with CHOKELLA®, in 1984 instant coffee with NESCAFE®,in 1986 chocolate powder drink with NESQUIK®, in 1996 growing-up milk with NESTLE® Çocuk, in 1989 coffee cream with COFFEE MATE® and in 2002coffee mixes with NESCAFE® 3in1.

Today, Nestlé operates from its multi production site at Karacabey in Bursa. Offering approximately 40 world wide known brands and 400 high standard products in 8 different food categories which appeal to Turkish consumers, Nestlé continues to maintain its leader-ship in most of the categories which it had introduced to the Turkish market.

After relying for years on the METTLER TOLEDO Statistical Quality Control System SQC52, Nestlé Karacabey deci-ded to upgrade its installation with the new Statistical Quality Control system FreeWeigh.Net®. Mr. Edgar Krappen, Factory Manager comments: “We have been using the METTLER TOLEDO SQC52 system successfully for years. This and the

2 METTLER TOLEDO Dairy & Beverages News 8

PublisherMettler-Toledo AG Industrial Heuwinkelstrasse CH-8606 Nänikon Switzerland ProductionMarCom Industrial CH-8606 Nänikon Switzerland Subject to technical changes © 11/2009 Mettler-Toledo AG Printed in the USA

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fact that the PC-based FreeWeigh.Net®, installed by the METTLER TOLEDO dis-tributor BAYKON, completely satisfied our needs, convinced us to proceed with this very successful partnership.”

Meeting customer needsPrerequisite for a successful installation was that existing scales and dynamic checkweighers – including third party – could be integrated into the system. Secondly, it was of great importance to have a perfect solution for hygienically sensitive environment and thirdly the system had to be user friendly especially for the operators at the test places.

FreeWeigh.Net® is designed to meet all these requirements. The PC-based Statistical Quality Control system enables sample based monitoring and documen-tation of parameters such as net content, expiration date, visual aspects of product and packaging, taste, etc. FreeWeigh.Net® offers – among others – the following core data: Production (time period) mean value, number of violations of the legally defined tolerance limits and mean stand-ard deviation of the production (time period). These parameters are required to fulfill legal requirements e.g. in regard to the national and international net weight legislation as well as to monitor, adjust and document all quality aspects of a product.

Seamless device connectivity BAYKON introduced a FreeWeigh.Net® sys-tem including fifteen ID30 PC-terminals, three remote PR balances and four dynamic checkweighers. Through the Device Integration Utility module of FreeWeigh.Net® BAYKON was able to inte-grate third party checkweighers besides the METTLER TOLEDO Garvens check-weighers. The optional Device Integration

Utility provides a configurable string parser for devices with communication interface and enhances FreeWeigh.Net® to an all-embracing quality insurance beyond weighing.

Practical, informative, user friendlyMr. Edgar Krappen comments: “Changing from SQC52 to the FreeWeigh.Net® system was successfully accomplished within one day after some pre-work and testing. Due to the very practi-cal and user friendly menus provided by the FreeWeigh.Net® soft-ware, our operators were able to adapt to the new system imme-diately.“

Net content control of Nescafe sticks, Maggi hardtablet bouillon and chokella spread at the FreeWeigh.Net® test places with ID30 PC-terminal

Dynamic checkweighers integratedinto FreeWeigh.Net®

Net weight control of semi-finished chocolate bars

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FreeWeigh.Net® –software scalability

At the test places operators weigh ran-dom samples of the various Nestlé products in a predefined interval and monitor statistical data. FreeWeigh.Net® stores and analyzes the measured values and immediately provides quality data information at all stations. Supervisors and operators can directly intervene if needed thus saving costs by avoid-ing unnecessary overfilling and wastage.

Mr. Edgar Krappen emphasizes: “Manual documentation and reports belong to the past. Due to the Data Export module and Excel Macros supplied by BAYKON, we are now able to automatically generate the Nestlé Standard QMS forms.

ID30 PC-terminal: Dustproof and suitable for cleaning with high-pressure equipment

FreeWeigh.Net® Modules at Nestlé Karacabey:

Testplace Module:The convenient – PC based – user interface for executionof random samples and testplans• Easy product selection on PC• Convenient design for touch-screen operation• Usable for Personal Computers or PC based terminals• Online graphics for active products

Device Integration Utility Module:Allows connection of measurement instrument toFreeWeigh.Net®, which are not supported with a dedicateddevice driver such as third party checkweighers, captorque measurement devices, rest oxygen detectors etc.• Provides a configurable string parser for devices with communication interface• Enhances FreeWeigh.Net® to all-embracing quality assurance beyond weighing

Attributes & Testplans Module:Input of product quality attributes from visual inspectionand execution of Testplans – linking individualmeasurements and checks together to a sequence• Ensures completeness of quality data• Simple operation• Graphical representation with Pareto charts showing the frequency of errors

Batch Handling Module:Ideal for customers working with batch oriented processes• Authorization of batch release in the batch catalog• Batch oriented statistics• Possibility for two concurrent batches

SPC Module:Statistical Process Control with• Control limits for mean value of random sample• Control limits for standard deviation and range

of random sample• CuSum• Cp/Cpk

Free Reporting Module:Allows highly customized reports:• Simultaneous display of selected related product

information in one report: – Activities / alarms – Combined variable / attribute-samples / statistics – Variables: mean value, standard deviation,

range control charts, histograms – Attributes: pareto, trend graphic for individual attributes, c-charts, u-charts• Freely selectable time period• Data pin-pointing allows filtering tolerance violators from the report.

Perfect for hygienic sensitive areasThe fifteen test places with ID30 PC-terminals fulfill Nestlé’s strict hygien-ic requirements. The stainless steel, IP69k protected terminals are ideal for hygienic sensitive areas where heavy cleaning pro-cedures are the standard. The terminal can even be hosed down with high pres-sure equipment. The ergonomic touch-screen terminal with its intuitive user guidance provides an easy-to-use data entry station at the production lines and the existing scales could be seamlessly connected to a terminal.


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Mr. Edgar Krappen concludes: “BAYKON’s technical power and the experienced local team in combination with the strong METTLER TOLEDO solutions convinced us to carry on the successful partnership. The hygienically designed floor scales, the outstanding performance of the Garvens checkweighers and the unrivalled preci-sion of the METTLER TOLEDO tank scale solutions stand for it.”

For more information: www.mt.com/freeweighnet

www.mt.com/batching www.mt.com/hi-speed

Stainless steel load cell

PUA579 floor scale with automated lifting device

Complete supplierFollowing the thriving FreeWeigh.Net® project BAYKON served Nestlé with fur-ther METTLER TOLEDO weighing solu-tions. Four new PUA579 floor scales with lifting device made for heavy wash down procedures were successfully introduced at various places in production.

The stainless steel low profile scale(35mm) is protected against prolonged submersion (IP68) and the automatic lifting device with gas springs provides easy accessibility for profound cleaning under the platform.

Additionally, several METTLER TOLEDO checkweighers and over forty tank scales were installed in the production area. The tank scales are equipped with METTLER TOLEDO load cells and IND130 smart weight transmitters. The hermeti-cally sealed stainless steel load cells are protected against submersion (IP68) and the digital connectivity between weigh-ing sensors and Nestlé’s Siemens S7 PLC is seamlessly provided by the IND130 Profibus® option.

IND130 smart weight transmitters


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g Highly Affordable Turbidity/Color Solutionfor Phase SeparationThe risk of process interruption due to using the wrong or a contaminated product must

be minimized if you want to optimize production. The new InPro 8300 RAMS series from

METTLER TOLEDO not only solves the problem, it is very cost-effective too.

Cost savingsIn the highly competitive environment of Dairy manufacture, cost optimized pro-duction is vital. To maximize production you need to know exactly when the water to milk phase separation is complete. To minimize loss at the filling line you must deter-mine the precise moment product and not water is flowing through the line. And you want to do all this with minimum expenditure.

RAMS does it allThe InPro 8300 RAMS optical product monitor is unique, versatile, compact and inexpensive. RAMS (Reflection Absorp-tion Multi-Switch) technology uses LEDs to measure the reflection and absorption of liquids. The absorption of near-infrared light is utilized to accurately and instantly determine when the transition of water to milk is complete. Using eight parameters determined by four LEDS, the InPro 8300 RAMS can identify up to eight differently colored liquids. This makes the monitor ideal for multiple-product filling lines.

Easy to install and maintainAll members of the InPro 8300 RAMS product family are easily installed on Tuchenhagen VARINLINE housings. They are further characterized by a reduced maintenance requirement thanks to the use of long-life LEDs and CIP resistant materials. The only calibration procedurenecessary for all InPro 8300 RAMS versions is a simple in-line zero point correction.

BenefitsLow installation cost■ Fast and easy installation on

Tuchenhagen VARINLINE housings

Reliable operation■ Use of silica gel in optical housings

eliminates error-prone usage of air purge installation

Fast, easy calibration■ Simple in-line calibration correction

with clear water

Very low maintenance cost■ Uses long-life LEDs, not bulbs

Excellent value■ Extremely attractive price/perfor-

mance ratio

Learn more at:

www.mt.com/InPro8300RAMS

InPro 8330 RAMS product monitor

Best Practice

Optimize product/water phase separa-tion control for higher efficiency.

To minimize product losses and to optimize process water recycling, in-line turbidity monitors provide more reliable and reproducible results compared to a sight glass or conductivity control.

www.mt.com/Turb


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The cult drink Jägermeister is the traditional brand of the Mast-Jäger-

meister AG, renowned world wide for its instant association with two

sympathetic stags and a wild "pub party" atmosphere with young adults.

Dynamic weighing technologyProvides quality assurance for Jägermeister

Jägermeister has, behind its modern and trendy image, a very long and traditional history. The company Mast-Jägermeister AG has been producing Jägermeister which is enjoyed in more than 80 countries around the world since 1935. The cordial Jägermeister is made from a total of 56 herbs, blossoms and roots and has always been produced and bottled in Wolfenbüt-tel. More recently the Mast-Jägermeister AG opened production sites in Kamenz in Saxony and Wittmar near Wolfenbüt-tel. The continuously rising sales figures prove that Jägermeister is an absolute

market success with more than 81 million bottles being filled with the mild yet spicy cordial in 2007. This impressive number strengthens the company’s position as the largest German producer of internation-ally distributed spirit specialities.

The main focus is on quality controlQuality is one of the key success factors for Mast-Jägermeister AG, a company with a very strong single brand. “Quality assur-ance is an extremely important subject in the Jägermeister production”, explains Jens Rießen, head of the Kamenz plant. “Due to our strong brand reputation we

are committed to making sure that our customers will always get the very best quality”, continues Rießen. At the Kamenz site in Saxony over 20 million litres of Jägermeister is bottled per year and since this modern facility commenced produc-tion the company Mast-Jägermeister AG has been relying on checkweighers from METTLER TOLEDO Garvens.

Key Benefits of the METTLER TOLEDO XE3 Checkweigher• Consumer protection and quality control

by automatic rejection of underweight or overweight products.

• Touchscreen with clear operator guidance for ease of operation.

• METTLER TOLEDO offers several XE checkweigher models for different weighing ranges and applications. Up to 100 product setups can be stored allowing for quick and easy product changeover.

XE3 Checkweigher checking completeness of cartons with bottles


The Principles of Checkweighing Guide shows manufacturers in all industry sectors with an automated production line, how to develop an effective product inspection program and achieve compliance with standards, legisla-tions and regulations. Furthermore, this guide explains in depth how an effective checkweighing program can improve efficiency, save costs, protect end consumers and ensure a consistent high quality.

Request your complimentary copy from

www.mt.com/pius-guide

Jägermeister started production in Kamenz in 1996METTLER TOLEDO supplied the dynam-ic weighing technology for completeness checking in the end-of-line packaging process where the weight of cartons filled with either “1 liter” or “0.04 liter” bottles is verified. This ensures that incomplete cartons or those containing bottles with too little content are detected and rejected, preventing them from leaving the factory. Moreover, the weight check ensures that damaged bottles with leaks are immedi-ately detected.

Mast-Jägermeister AG trusts in METTLER TOLEDO innovativenessMETTLER TOLEDO checkweighers can be integrated near to every production line as their design can be easily adapted to the given technical requirements of any pro-duction line. An example of this is where two weighing terminals of two separate “E Series” checkweighers, integrated into different production lines, were installed side by side, remote from their weigh-frames, allowing for easy operation of both checkweighers from one position. A solution that was highly appreciated by the staff operating the Jägermeister pro-duction lines.

The XE3 is a very cost effective state-of-the-art dynamic weighing technology solutionAn XE3 checkweigher weighing 60 car-tons per minute is also in use at Mast-Jägermeister AG. In this application the

XE3 can weigh products up to 6000g with an accuracy of up to 1g. The XE3 automatically rejects underweight car-tons by means of a pusher, enabling the line staff to check the carton and replace bottles where necessary. This method ensures that only full bottles reach the end consumers.METTLER TOLEDO checkweighers are instrumental in supporting the quality management of Mast-Jägermeister AG and protecting the Jägermeister brand.

www.mt.com/hi-speed

Dynamic weighing technologyProvides quality assurance for Jägermeister

Two remote 'E Series' weighing terminals (separate from weigh frames) – for easier access

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Making Sense of Floor Scale Choices

If you’ve been in the market for a new floor scale recently, you may have

been overwhelmed by the range of choices out there, and the wide range

of prices. So what makes one floor scale a better choice than another?

There are many factors that affect a floor scale choice, but let’s start with the basics and look at three decisions points:

Size and CapacityA floor scale can be made in just about any size or capacity. A 4’x4’ 5000lb scale is by far the most popular choice for most buyers and it is the size and capacity that is usually referenced when an advertise-ment includes price information. Most manufacturers offer a range of “standard scale sizes” and many also offer custom sizes and capacities. Expect to pay a little more for a custom-sized floor scale vs. a standard one, even if the square footage of each scale is virtually identical.

MaterialGenerally speaking, floor scales are made with stainless steel for food, pharma and chemical applications, and mild steel is used for most other applications. Stainless steel units are usually built with a smooth plate weighing deck, and mild steel units are typically fabricated with a treadplate deck, although both are available in either style. METTLER TOLEDO also offer stain-less units in two versions: 304 and 316.

Frame vs. Footed DesignMany people don’t even know this choice exists, but it can be a critical selection point, depending on your application. Full frame scales are generally more expensive,

but offer superior protection for end load-ing applications. A frame also provides ex-cellent side load protection, a must when a scale is in a high forklift traffic area. A footed scale is less expensive to build and buy, but does not offer the same level of performance as a frame-type floor scale. Either version can be made in most sizes and capacities.

Installation choicesThe majority of floor scales purchased are surfaced mounted, meaning the scale is placed directly on the floor, leveled and calibrated. Often one or more ramps are added to the scale to make it easier to load the scale, especially when loading it with totes or hand carts since the scale’s weighing surface is usually a few inches above the floor surface. Surface mounting is simple and relatively fast, and makes future relocation of the scale easier. How-ever, there are applications where it is pref-erable to use a pit-style installation. Pit mounting allows the scale’s weigh-ing surface to be flush with the floor. The primary advantage is the convenience of allowing easy loading of the scale from any direction, plus the ability to locate the scale virtually anywhere, since it is flush with the floor surface. Pit mounting also has some other advantages, especially in areas where the scale needs to be cleaned on a regular basis, such as a food or phar-maceutical production area.

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1 Rocker pin automatically aligns in blind hold load point, concentrating all verti-cal load at one point on the load cell. More durable than the threaded connec-tion on a footed scale.

2 Fixed end and side bumpers protect load cells from side-loading damage

3 Overload protection stop prevents dam-age to the load cell

4 Hermetically sealed, stainless steel load cells are needed in all washdown appli-cations and prevents moisture and dust damage in dry applications.


Standard shipping floor scale with ramps

The pit is typically a few inches deeper than the scale height, and may be a dry type (without drain) or wet type (with drain). The pit is often lined with tile to allow easier cleaning. Many pit installa-tions use floor scales equipped with lifting mechanisms to provide complete access to the underside of the scale and the pit for thorough cleaning. The two main disadvantages of pit instal-lations is cost and future relocation. Con-structing a pit is an added expense vs. sur-face mounting, plus if the scale needs to be relocated in the future, a new pit must be constructed and the old one filled in.

A recent innovation from METTLER TOLEDO is the stainless steel pit liner. It eliminates the need for tile linings by providing a smooth stainless steel pit wall

Portable floor scaleIntegral wheels allow easy movement from site to site. Ramps, provide easy access to the weighing surface and can be folded up when moving.

and floor. It also simplifies the pit-design process by allowing the use of a rough hole that the liner is positioned over, and then backfilled with concrete. If a drain is required, the liner can be equipped with a drain connection. Once the liner is in place, the floor scale can be installed and calibrated for use. Pit liners also allow easy pit-type installations in mezzanine locations by attaching the liner directly to the mezzanine structure.

Specialty ScalesSometimes a specialty scale is the best so-lution, especially when the scale is being used for a very specific application. For example, portable scales are very popular in applications where a single scale needs to be moved from room to room or around the production facility. These scales have wheels which deploy when moving and

tuck away when the scale is in use. Scales are also available where the scale deck or even the entire scale tilts or lifts off the floor into a vertical position. These are handly for applications where the scale need to be cleaned often or where the scale is located in a high traffic area and needs to be lifted out of the way when not in use.

Other specialty scales include barrel scales, U-scales for pallets, coil scales, cylinder scales, clorine tank scales, and “pancake” scales which are equipped with ramps on all for sides and the corners to allow access from any direction at all.

You can learn more about all of METTLER TOLEDO’s floor scale offerings at

www.mt.com/floor-scales

Vertex SS pit liner


METTLER TOLEDO has published a range of authoritative guides and white papers that cover focus areas which enable you to select the right solutions to improve your processes.

Free technical guidesThese guides offer support in installing an all-encompassing product inspection program and provide advice to help you in achieving compliance with standards, regulations and legislation. Request your free guides: www.mt.com/pius-guides

Regulatory compliance white paper Learn how fulfilling regulations can offer multiple oppor-tunities to increase your quality, to save costs and to increase your profitability and productivity. www.mt.com/ind-regulatory-compliance

Statistical Quality Control guide Day after day, thousands of millions of packages of all kinds are filled. This guidebook is a "must-have" for anyone engaged in filling operations! www.mt.com/sqc-guide

Use www.mt.com as a Work Efficiency Resource

Join a wide array of webinars to learn about various topics from choosing the right technology to process optimization.

We offer both Live Webinars where you can speak directly with our specialists and recorded On Demand Webcastswhich are available at your convenience, 24 hours a day.

View the full range of webinars: www.mt.com/webfood

Webinars – Learn more with little time and effort

Free guides and white/technical papers

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SafelineMetal DetectionGuide

Hi-SpeedCheckweighingGuide

SafelineX-ray InspectionGuide

RegulatoryComplianceWhite Paper

SQCGuide


Download our calculators and work out how much you could be saving.

Colored weight control system saves both time and money: www.mt.com/ind-colorweight-calculator

Save money with quality control and correct filling: www.mt.com/sqc-calculator

Eliminate unnecessary costs during formulation and maximize your profitability: www.mt.com/formulation-calculator

Know-how – tips & tricks for daily work improvements

As an industry leader, METTLER TOLEDO have a wealth of material to help educate and inform you about product inspection and industrial weighing solutions.

What can x-ray inspection do for you?Learn how x-ray inspection can benefit your business including: contamination detection, mass confirmation and identification of missing, mis-shapen or broken products. To learn more visit: www.mt.com/benefitsofxray

Avoid bacterial contamination with hygienically designed equipment METTLER TOLDEO provide solutions to help you to improve food safety and to comply with food safety standards like IFS, SQF, BRC, ISO 22000 or HACCP. www.mt.com/ind-hygienic-design

Value calculators – find out how to save money

Industrial Weighing catalogSolutions for weighing and measuring in industrial production www.mt.com/ind-catalog

Food and Beverages brochureSolutions to improve food safety, product quality and productivity www.mt.com/ind-food-brochure

PowerPhasePRO metal detectorsMETTLER TOLEDO Safeline PowerPhasePRO metal detectors provide the ultimate in metal detection performance. They help manufacturers increase productivity, reduce overall manufacturing costs and improve competitiveness. www.mt.com/safeline-powerphasepro

Product Inspection catalogDownload the PI Guide brochure for more details on Hi-Speed checkweighers and Safeline metal detectors and x-ray inspection systems. www.mt.com/pius-catalog

Download comprehensive product documentation

Webinar: Food RegulationsLearn how to comply with food regulations and improve your productivity.

www.mt.com/wefood

Register for free Webinars:

Free Technical Guides and White PapersHelp You to Make an Informed Decision

METTLER TOLEDO has published a range of authoritative guides and white papers that cover focus areas which enable you to select the right solution and service for improvement of your processes. To register for your free guides please visit: www.mt.com/pius-guides www.mt.com/ind-regulatory-compliance

SafelineMetal DetectionGuide

Hi-SpeedCheckweighingGuide

RegulatoryComplianceWhite Paper

SafelineX-ray InspectionGuide

For more informationwww.mt.com/ind-dairy-beverages

Your METTLER TOLEDO contact:

USAMettler-Toledo, Inc.1900 Polaris ParkwayColumbus, OH, 43240Tel. (1) 800 523 5123

CanadaMettler-Toledo, Inc. 2915 Argentia Road, Unit 6Mississauga, Ontario, L5N 8G6Tel. (1) 905 821 4200

USAMettler-Toledo5 Barr RoadIthaca, NY, 14850 Tel. (1) 800 836 0836

USAMettler-Toledo Safeline6005 Benjamin RoadTampa, Florida, 33634 Tel. (1) 800 447 4439

A Wide Range of Solutionsto Improve Processes1. BBA449 over/under check scale with colored backlight2. IND780 Process terminal3. DL22 Food & Beverage Analyzer4. Safeline metal detectors and x-ray inspection systems

Yellow – weight above tolerance

Green – weight within tolerance

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