Food & Beverage Analysis

Formulation of Food
& Beverage Recipes

Balances

The Ultimate Formulation Guide

Proven Methods & Procedures
Creation of food mixtures is a hot topic. With regards to the development of functional
food, also called nutraceuticals, or the reduction of salt in processed food, it is clear that
the requirements for creating new food recipes and weighing individual food ingredients
have become more demanding. Many formulations have to be tried until the ultimate
recipe is found.

The following guide will:

• Give an introduction to the topic

• Present the different methods of laboratory and industrial formulation
• Give tips and hints for easier formulation on laboratory and industrial balances

Content 2

1. The Importance of Formulas 3
2. Different Requirements in Laboratories and Production Lines 3
3. Formulation: An Important and Challenging Application 4
3.1 Formulation Method 4
3.2 Risks during Formulation 4
3.3 Manual Formulation 5
3.4 Available Instruments for Formulation 5
3.5 Formulation Devices for the Lab 5
3.6 Compliance, Networking, and Central Control with LabX Balance 6
3.7 Measurement Accuracy Is Often Undervalued 7
3.8 The Highest Efficiency during Formulation in Production 9
3.9 Consistent Product Quality, Guaranteed 9
3.10 Good Weighing Practice (GWP ) 10
™ ®

4. Conclusion 11

METTLER TOLEDO Formulation Guide 2

1. The Importance of Formulas

Whether in research, development, or production, creating multi-component mixtures according to given formu-
las is one of the most important standard tasks in many industries. This is particularly the case in food produc-
tion, which often follows clever, tried-and-tested formulas. These formulas must be followed exactly time and
time again in order to maintain consistent product quality. In the food industry, weighing errors can have not just
financial but also health-related consequences.

At the same time, the industry is under tremendous pressure to succeed while keeping costs low. For this rea-
son, it is necessary to refine and optimize formulas in order to improve the taste, appearance, shape, and shelf
life of the products. Regulations governing the use of certain ingredients must also be followed, and these regu-
lations are constantly changing as new knowledge comes to the fore.

These days, formula development is precisely documented. The reports generated during this process serve as
proof to support quality or shelf life claims and hold information on the right mixture and other data.

It is for these reasons that weighing systems for formulation processes must provide high precision, maximum
reliability, and traceability. METTLER TOLEDO's weighing systems for the lab and production meet these chal-
lenges and are presented in the following.

2. Different Requirements in Laboratories and Production Lines

Food industry labs focus a majority of their efforts on further developing the product range. New ingredients are
tested, and existing ingredients are reduced. The aim is to constantly improve the taste, consistency, shelf life,
color, appearance, and aroma of the foods. In doing so, the formulas frequently undergo only slight changes,
and the weighing systems in use must provide support that is as flexible as possible to accommodate these.
Working with balances that operate with just a few milligrams or grams allows to limit the use and costs of ma-
terials and ingredients.

Production lines have different requirements: the weighing range is larger and the requirements focus on speed
and efficiency. The ability to connect the balances to an existing LIMS (lab management system) or ERP (enter-
prise platform) system such as SAP is usually an important requirement for the weighing systems. Comprehen-
sive networks like these ensure efficient goods management. Data from purchasing, storage, production, and
accounting are electronically compared, reducing the risk of error and costs simultaneously.

In labs, these networks provide central access to all connected balances and allow all measurement values to
be automatically saved. METTLER TOLEDO provides specially tailored instruments for both of these areas of ap-
plication, ensuring a high degree of weighing reliability and cost-effectiveness.

METTLER TOLEDO Formulation Guide 3

3. Formulation: an Important and Challenging Application

Formulation is one of the most important tasks particularly in the food and beverage industry. Formulas used for
food and beverage production frequently comprise over 10 or 20 different components. In addition to basic raw
ingredients and spices, products usually contain additional vitamins, colorants, taste enhancers, or preserva-
tives. Some components are only added to formulas in tiny amounts. The biggest challenges in respect to for-
mulation are the broad weighing ranges and the complexity of the recipes.

XPE205 analytical balance Universal weighing system ICS469
For small amounts For bigger amounts and elaborated formulations

Fig. 1: METTLER TOLEDO offers the perfect weighing systems for labs and production lines, providing extensive support to users in their
special tasks

3.1 Formulation Method

The formulation method is simple and can be easily explained: First the right balance for the weighing task in
question is selected. Then a suitable weighing container is placed on the balance and the device is tared. The
balance is then zeroed and the first component is weighed. Once the specified value is reached, the weight is
noted and the balance is zeroed again. This procedure is repeated until the weighing of all components is
complete and all measurement values have been recorded.

3.2 Risks during Formulation

Each weighing step carries the same risk of error that any weighing process faces. Typical sources of error
include electrostatic charge, sample spills, external influences, and operating errors.

It is most difficult to reach the specified target weight of each component. Particularly when powders are being
weighed, if too much product goes into the weighing container and the maximum permissible tolerance is ex-
ceeded, the entire weighing process is invalidated. All dispensed components up to that point are lost, and
valuable working time is wasted.

Predominately in the search for new formulas in labs, the initial weight of a component may fall below the set
minimum weight of a balance. If this occurs during the weighing process, the formulas must be repeated with
larger quantities, wasting time and materials.

The risk of error increases with each new individual item in a formula. Mixtures with lots of components therefore
present a considerable risk.

The manual transfer of weighing data into a lab journal and then an electronic database is a source of two
typical errors particularly in manual formulation, which greatly affect weighing reliability.

METTLER TOLEDO Formulation Guide 4

3.3 Manual Formulation
All steps of the process are carried out by the user; every press of the buttons and every record of the weighing
results. The user must also ensure that the formula is followed and no ingredients are omitted.

At the end of the formulation process, the actual final weight of the product can be compared with the theoretical
value calculated from all recorded individual weights in order to check the accuracy of the process. If both val-
ues fall outside of a previously defined tolerance, the formula is invalid and must be repeated.

The final transfer of values into Microsoft Excel or an existing database system is a further step in the manual
process.

While this process seems to be simple, quick, and reliable at first glance, modern solutions shed light on its
weaknesses and shortcomings.

3.4 Available Instruments for Formulation

METTLER TOLEDO provides a number of clever weighing and software solutions that help minimize risks during
formulation and address the weaknesses of the manual process. Correct and traceable work in the food industry
is an absolute must, if only because of the health-related consequences.

In the lab, the analytical and precision balances support formulation through
– weight calculation and data management as per 21 CFR Part 11
– weight calculation via multiple balances directly connected to a network
– freely configurable totalization application that can be saved as a method
– entry of up to 255 components for each formulation process and alphanumerical component identification
– user-friendly, intuitive menus via balance display or PC
– flexible weighing process thanks to numerous options: additive or individual dispensing, automatic weight
­determination, taring, pre-taring, deletion of last sample, overwrite function
– comprehensive documentation with component identification, and component totals and weighing parameters
– automatic storage of all data on an SQL server database

For production lines, METTLER TOLEDO provides a range of very robust, flexible, and precise industrial ­balances.
The dispensing and formulation system, FormWeigh.Net®, functions as an intelligent interface between the
­balances and ERP system to control the complete formulation process and manage material flows. This ­ensures
consistent product quality, maximizes raw material usage, and increases process speeds. FormWeigh.Net®
­features the following benefits:
– easy operation and creation of different formulation methods
– complete traceability of the entire production process
– central data management, reduction of material losses, and intelligent goods management
– fast material/data flows and reliable data storage
– batch-oriented workflows from incoming to outgoing goods
– partial batch management and quantity correction
– functions meet 21 CFR Part 11, 21 CFR Part 111, and EU 178/2002
FormWeigh.Net increases cost-effectiveness, reliability, and efficiency in industrial formulation processes.

3.5 Formulation Devices for the Lab

Whilst formulation with conventional balances is only a manual step by step procedure, balances from METTLER
TOLEDO offer more. Formulation and totalization are integrated in the balance as standard weighing programs
and provide automated user guidance.

METTLER TOLEDO Formulation Guide 5

The advantages are clear: XPE balances can be configured to the user's requirements with just a few settings in
the stored formulation program. Once created, the customized method can then be accessed permanently with
just one touch of the touch display. The formulation process follows the procedure described above, yet each
step is shown on the display once the method has been started. Measurement reliability, user comfort and
traceability are greatly increased as a result.

Once tared, the balance is automatically zeroed simply by waving a hand over the infrared sensor SmartSens.
A printer can optionally be connected to print the first result or a label for the tare container, which can then be
used to uniquely identify the formula from that point.

When an ingredient is being weighed, the display indicates the weighing value via the SmartTrac function. Once
the value specified in the formula is reached, a green bar indicates that the weight falls exactly within the set tol-
erance range. The user than tares the balance again by waving a hand over the SmartSens infrared sensor and
follows the next instructions on the balance display.

The result is automatically transferred to and totaled in the buffer

memory. Thanks to this tool, interruptions to the weighing process are
not a problem. If in doubt, the user can read back the weighed com-
ponents on the balance display at any time. Every measurement value
and the total weight are recorded in the printout. The total weight is also
displayed on the balance. The printout helps with checks and documen-
tation and can be pasted into the lab journal. The Excellence Plus bal-
ances can store up to 99 components, plenty of space for comfortably
working without stress or errors on standard formulas that hardly need
to be adapted.

XPE1203S Precision Balance

Fig. 2: The Excellence balances make formulation in the lab easy thanks to integrated standard formulation programs

3.6 Compliance, Networking, and Central Control with LabX Balance

LabX Balance brings the user one step closer to more reliability, better traceability, and higher levels of user
comfort. This software module links all balances into one network. Quality supervisors or lab managers can
freely define their own formulas, user authorizations, read/write rights, and a number of other security param-
eters.
All settings can be applied to either certain balances or all connected devices. Manual entries are thus made ob-
solete. All measurement values are automatically calculated and saved.

Interfaces allow data to be exported into Microsoft Excel or an LIMS system. Any product databases can be
added to this function. Customers can build up their own process system with their own products. Forms, print-
outs, and data exchange between the balances and SAP, for example, are all possible with LabX software PCs
no longer have to be connected directly to the balance. Database access via Ethernet or WLAN is also an option.

Fig. 3: LabX links the METTLER TOLEDO instruments in your lab and allows
central control, monitoring, and data management

METTLER TOLEDO Formulation Guide 6

3.7 Measurement Accuracy Is Often Undervalued
The pivotal point in formulation is the weighing. However, even here the risk of some errors is constantly under-
rated. Ultimately the weighing accuracy plays a very important role particularly with the very small weights typi-
cal in lab settings. What is the use of a sufficiently precise SOP when the weight value falls below the minimum
tolerance, for example, or when a balance simply is not calibrated, the required measurement accuracy is not
known, or the balance has been set up in a bad location?

In all cases the displayed weighing results may deviate significantly from the actual values. Seeking out possible
sources of error after they occur is very time-consuming and cost-intensive, which is why eliminating the most
important sources of error as much as possible in advance is a worthwhile endeavor. These errors include:
– operating errors (minimum tolerances, measurement accuracy, calibration, logging, etc.)
– general and/or systematic errors (poorly selected location, environmental influences, etc.)

Operating Errors:
Human error: In additional to systematic sources of error, humans are of course the focus of balance operation.
The easiest errors happen simply because values have been incorrectly recorded. Manual notation should there­
fore be avoided as much as possible. All balances from METTLER TOLEDO provide the option of connecting an
external printer or exporting the measured values to a connected PC via Ethernet, USB, Bluetooth, or WLAN.
This eliminates errors caused by mixing up samples or incorrectly recording data. In an increasingly hectic labo-
ratory environment, this risk increases particularly during complex weighing processes such as those carried
out during formulation. If the phone rings or users are otherwise distracted during weighing, errors are bound to
occur.

Minimum tolerances: If the measured sample weight falls below the minimum permissible weight of a
balance, measurement errors drastically compound and the permitted tolerance range is quickly breached.
The microbalances, analytical, and precision balances of the XPE, XS, and MS-TS lines, are all fitted with the
MinWeigh function. A visual warning is indicated by a red weight value when the permissible minimum
weight is breached (see Fig. 4).
This function protects against weighing errors but cannot prevent lost time or materials when the weight value for
a component falls below the minimum tolerance right at the end of a formula.

Centering the weighing container: If weighing containers are not centered on the weighing plate, measurement
errors may occur. This risk increases as the sample weight increases and depending on how off-center the con-
tainers are.

Touchscreen display of XPE Analytical Balance (LevelControl and MinWeigh)

Fig. 4: Safety functions such as LevelControl and MinWeigh reliably protect against typical errors

METTLER TOLEDO Formulation Guide 7

SmartGrid: Spilled samples may cause measurement results to be incorrect. If the materials fall on the weighing
plate instead of in the opening of the weighing container, the weighing results will be incorrect if this goes unno-
ticed. METTLER TOLEDO's SmartGrid grid weighing pan eliminated this risk. Spilled sample materials fall through
the grid where they can no longer affect the measurement. This innovation has two further advantages:
• SmartGrid offers very low resistance to drafts. For this reason, measurement values can stabilize more quickly
than with conventional balances. This benefit is particularly useful with frequent weighings such as formula-
tions or larger numbers of samples.
• The weighing grid itself is hung on the rear side of the balance and can be easily removed, allowing for faster
cleaning. Because the weighing grid is hung, the entire weighing chamber can be easily accessed for clean-
ing. The weighing surface is smooth, without corners or edges, eliminating the risk of dirt accumulating.

SmartPan: Use a SmartPan™ weighing pan optimized for minimal airflow resistance. SmartPanTM limits air-draft
disturbances and in most of cases avoids the inconvenience of a draft shield while improving weighing speed
and precision. SmartPan™ is standard for METTLER TOLEDO Excellence precision balances.

ErgoClips: A range of different holders that fit the SmartGrid, METTLER TOLEDO's ErgoClips ensure the perfect
hold on all established types of tare container, such as test tubes, round-bottom and volumetric flasks, and
weighing pans. The weighing containers are secured into an ergonomic, optimal position.

Fig. 5: SmartGrid offers three advantages in one: quick weight stabilization, easy cleaning, and reliable weighing results.
A large number of ErgoClip solutions ensure a secure hold on the tare containers

Systematic Errors:
Location: The location where a balance is set up can greatly affect measurement accuracy. Balances should be
set up on a stable, non-magnetic surface that is as vibration-free as possible. Select a location that has as few
drafts as possible, i.e., not next to doors or windows, heating systems, air conditioners, infeed/outlet air valves.

Temperature, thermal radiation, air humidity and electrostatic charge: Weighing results depend on tempera-
ture, which is why consistent conditions in the weighing chamber help achieve reproducible results. Direct sun-
light or thermal radiation from light sources also affects the weighing result.

Several weighing solutions from METTLER TOLEDO are fitted with a fully automatic motorized self-calibration
function (FACT) or an integrated temperature control program (ITC and ATC). These functions help eliminate er-
rors caused by temperature.

Relative air humidity also has an effect on the results. The air humidity should not fall below 20% or exceed
80%, and would ideally be between 45% and 60%.

This range also helps reduce the risk of problems with electrostatic charge. This effect often occurs when non-
conductive weighing containers made of glass or plastic are used, or when weighing very dry substances. Due
to the very slow process of electrical discharge, a drift occurs in most cases, meaning that hardly any reproduc-
ible weight consistency can be achieved. The analytical XPE balances are equipped with the unique StaticDetect
technology, which detects electrostatically charged samples or containers. A warning message is issued if the
weighing error exceeds the user-defined limit, and a block on release of the weighing result may be imposed.
The integrated antistatic kit in the XPE balances allows for a quick and hassle-free elimination of the static
charge. For other METTLER TOLEDO balances, this kit can be ordered separately as an accessory.
METTLER TOLEDO Formulation Guide 8
Weighing bench: If the balance is not absolutely level, precise results are impossible to achieve. All balances
from METTLER TOLEDO are fitted with a level indicator, allowing for quick leveling. XPE, XS and MS-TS balances
automatically check the leveling. If the balance was moved during cleaning, for example, LevelControl automati-
cally emits an acoustic signal to warn that the balance is no longer level. At the same time the display shows the
individual steps for leveling the balance again (see Fig. 4).

Fig. 6: Typical sources of error during weighing

3.8 The Highest Efficiency during Formulation in Production

In production other factors play important roles in formulation in addition to precision and reliability: efficiency,
speed, and traceability. In other words, fast, reliable, precise weighing and ideally a digital connection between
weighing systems and ERP/EMS systems. This allows for automatic regulation of stock levels and complete
documentation for each batch. The dispensing and formulation system, Formweigh.Net® from METTLER TOLEDO,
provides exactly these performance features. All METTLER TOLEDO industrial weighing solutions can be operated
with this software. Different terminals, connected on site to the weighing system, act as interfaces between the
PC and balance.

3.9 Consistent Product Quality, Guaranteed

The system initiates the stored formulation programs and save all measured values automatically in a trace-
able electronic database. The automatic process provides consistently high quality and high process reliability.
­Material losses caused by errors in the composition of individual batches are eliminated as a result. Pending
orders not yet executed are highlighted on the display, and processes which have already been carried out are
marked. The simple, clear user guidance is another plus. In tasks that require the four-eye principle, Formweigh.
Net can provide the second pair of eyes. It automatically selects the correct balance for a formulation task and
detects the raw material via a barcode scanner. The system thus optimizes the use of raw materials, following
the "first in, first out" principle. Disposing of expired raw materials is a thing of the past, meaning that disposal
costs as well as material costs are reduced. This is a solution that greatly contributes to increased efficiency and
profitability.

Fig. 7: Different displays act as the interface between the balance and PC

Formweigh.Net can be customized as required to suit all established company software systems such as SAP.
The standard interfaces for ERP/EMS systems make it possible to exchange raw material and order data. Master
data and information on stock levels no longer have to be re-entered. Information is constantly synchronized via
communication between the systems. Stock level information is always up to date, batches can be traced, and
interventions or changes can be organized centrally.

METTLER TOLEDO Formulation Guide 9

Fig. 8: Formweigh.Net controls your entire production sequence and communicates with your ERP system as required

3.10 Good Weighing PracticeTM (GWP®)

METTLER TOLEDO's program, GWP®, is a developed guideline used to ensure the measurement quality and
reliability of a balance in the long term. Within this program, the individual measurement risk is assessed in
advance. In doing so, the initial weighing, required measurement accuracy, and consequences of any errors are
calculated based on the specific customer needs. The entire installed base of scales and balances can then be
verified (GWP® Verification) if the customer desires. This verification is especially important to ensure that the
measurement error of the balance used for the formulation falls within the required tolerance. These solutions
can ensure consistent formula quality.

The program also provides clear recommendations for routine testing. The best balance and the perfect setup lo-
cation are useless when the balance is not regularly inspected. Over time, every balance is subjected to changes
that must be corrected by regular calibration/adjustment. Balances of the Excellence XPE and XS, as well as Ad-
vanced MS-TS and ML-T series are fitted with FACT and undergo regular internal calibration. This does not make
calibration with external certified weights obsolete, but it does increase the intervals between calibration.

The GWP program recommends possible calibration intervals, the required weights, maximum permitted toler-
ances, and measures to undertake when calibration intervals have not been observed, based on customer's
processes and risk assessment..

Fig. 9: The GWP program ensures reliability, efficiency, and user

comfort. The regular calibration of a balance and the right routine
tests are essential

METTLER TOLEDO Formulation Guide 10

4. Conclusion

Formulation is a central task in labs and production lines in the food industry. METTLER TOLEDO's solutions
provide more reliability, user comfort, and efficiency during weighing. A number of innovative weighing solutions
help to protect against errors as much as possible. The Formweigh.Net software is perfect for use in production,
where speed and material flow optimization are also an important factors. The option of connecting to an ERP
system such as SAP means higher process stability and profitability.

More Information
If you liked this guide, we are proudly presenting the METTLER TOLEDO series of guides for the food industry.
Please click on the below links to get access to the respective food guides.
The Ultimate Sugar Guide www.mt.com/sugar-lab
The Ultimate Acidity Guide www.mt.com/acidity-lab
The Ultimate Salt Guide www.mt.com/salt-lab
The Ultimate Edible Fats and Oils Guide www.mt.com/fat-lab
The Ultimate Moisture and Water Content Guide www.mt.com/moisture-lab

METTLER TOLEDO Formulation Guide 11

Good Measuring Practices
Five Steps to Improved Measuring Results

Good Measuring Practices by METTLER TOLEDO is a global program sup-

porting you in laboratory and production environments with quality assur-
ance measures for balances, scales, pipettes and analytical instruments.
The five steps of all Good Measuring Practices guidelines start with an
evaluation of the measuring needs of your processes and their ­associated
risks. We also take into account regulatory requirements and norms
­relevant to your industry.
With this information, Good Measuring Practices provide straight forward
recommendations for selecting, installing, calibrating and operating of
weighing and measuring instruments.­

www.mt.com/gwp for weighing

www.mt.com/gtp for titration
www.mt.com/gpp for pipetting
www.mt.com/gdrp for density and refractometry

5
Routine 1
Operation Evaluation

Good
Measuring
4
Calibration / Practices 2
Qualification Selection

3
Installation /
Training

www.mt.com
For more information

Mettler-Toledo Group
Laboratory Division
www.mt.com/contacts

Subject to technical changes

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