Dairy & Cheese

Industrial Weighing and Measuring

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Excellence in Quality Control in Nestls Ice Cream Production

Comprehensive and efficient quality control is a must for the world leader in the food industry. For almost 30 years, Nestl in Guadalajara (Spain) has been supported by METTLER TOLEDO weighing and Statistical Quality Control (SQC) solutions. The Nestl ice cream production plant in Guadalajara produces around 20 million liters per year. Products are distributed across Europe as well as to oversea countries like Chile and Australia. Compliance with Nestls strict quality requirements and net weight legislation demands an efficient quality control system. With METTLER TOLEDO FreeWeigh.Net software Mr. Gerardo Bermejo Barrera, Head of Quality Assurance, has an excellent networked system in place to monitor and control quality parameters directly at the production lines. semi-finished and finished ice cream products. Five test places, equipped with a PC including FreeWeigh.Net software and BBA compact scales, are installed in the production area, number six is located in the central laboratory. The networked topology with FreeWeigh.Net software running at every test site and a centralized Microsoft SQL database enables operators to execute the same quality tests at every station. Statistical Quality Control (SQC) provides quality information based on random sample data. FreeWeigh.Net offers among others the following core data: Networked Statistical Quality Production (period) mean value Control Number of violations of the legally At six different test places, line operadefined tolerance limits tors control quality parameters such as Mean standard deviation of the procolor, taste, weight or expiry date of the duction (period)

Statistical Quality Control

These parameters are required to fulfill legal requirements e.g. in regard to the European net weight legislation and -marking. Mr. Gerardo Bermejo Barrera continues: FreeWeigh.Net lets us know immediately if overfill occurs. It helps us to substantially reduce unnecessary overfilling as well as complying with net weight regulation. Due to FreeWeigh.Net only a click of a mouse is needed to retrieve current and historical production data which lets us regularly account for overfilling costs.

FreeWeigh.Net test place with PC, BBA4-series compact scale for net content control, visual inspections and other attributive tests

Quality parameters of semi-finished products With FreeWeigh.Net Nestl controls and monitors three important product parameters at once: ice cream weight, chocolate weight and volume (density). Chocolate is the most expensive part of

the ice cream. With this method Nestl can precisely account for the raw material and optimize production. Volume or density determination is not only necessary to control quality but also to fulfill legal regulations, while at the same time minimizing give away.

Publisher Mettler-Toledo AG Industrial Heuwinkelstrasse CH-8606 Nnikon Switzerland Production MarCom Industrial CH-8606 Nnikon Switzerland MTSI 44099116 Subject to technical changes 06/2007 Mettler-Toledo AG Printed in Switzerland

1. Determination of ice cream weight (the weight of the cookie is known and considered stable)

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2. Determination of chocolate coating weight: Gross weight of the finished ice cream minus ice cream weight (determined in step 1)

3. Volume (density) determination in water: The measured weight during submersion of the ice cream in water is equivalent to the volume of the ice cream.

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Statistical Quality Control

Quality parameters of finished products Every 15 20 minutes the net content of a sample of four finished ice cream products is monitored. But FreeWeigh.Net allows Statistical Quality Control far beyond weighing. Quality attributes such as correct product labels or barcodes, product expiry data and packaging are entered in preconfigured masks of FreeWeigh.Net, allowing subsequent graphical representation with easy to understand bar- or pareto charts. Product quality attributes are tested on an hourly basis. In addition to the net-, ice cream weight, chocolate-weight and volume, Nestl monitors the complete product and package quality parameters.

Attributive tests: correct net weight, barcode, expiry date, box aspect and label control of finished products

FreeWeigh.Net Statistical Quality Control at Nestl

Product quality parameters Ice cream weight Chocolate coating weight Volume (Density) Taste Color

Package quality parameters

Typical FreeWeigh.Net monitoring screen showing ice cream weight, chocolate weight and volume (density)

Net weight Barcode Expiry date Label Box aspect Plastic wrap

Customizable test reports

Mr. Gerardo Bermejo Barrera concludes: During our long-lasting relationship with METTLER TOLEDO, we have always implemented innovative solutions from a competent system specialist. FreeWeigh.Net

gives us the flexibility we need in terms of quality control and documentation. The system with its intuitive setup is easy-to-use after a short training period and allows us to generate customized test

reports. Time-consuming manual data collection is completely obsolete helping us to improve productivity, comply with regulations and avoid unnecessary overfilling.

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Parmalat Expands with Safeline Metal Detectors

Parmalat has chosen to work with leading metal detector producer, METTLER TOLEDO Safeline to ensure it achieves the highest possible levels of sensitivity to metal.

Parmalat Dairies UK Ltd has undergone a substantial expansion programme, requiring an upgrade of its production lines. The company manufactures yoghurt, cottage cheese and dairy dessert products under its own label brands, Lakeland and Loseley, and also for the major UK retailers. A top priority for Parmalat is product quality control. Product effects METTLER TOLEDO Product Inspection Sales & Service Manager, Mike Bradley, comments, Wet dairy products are especially challenging for metal detection systems because they have their own level of electrical conductivity. This contribution by the product to the overall task

faced by the detector is known as product effect and all metal detectors have to deal with it effectively to detect metal contamination. Safelines high frequency signature detection system is especially suited for such demanding products because of its ability to screen out product effect and handle different product types and sizes with the minimum of product settings.

The double-headsystems offer complete flexibility for Parmalat which can switch from one detector head to the other depending on whether the pots being monitored have film or foil lids.

Parmalat Group Operations Director, Clarence McAteere explains, The double head systems are important because it means we can handle different product packaging on the same line. We decided to work with Safeline because of Foil and film lids their quality reputation, the standard of Parmalat has installed eight Safeline detec- their technology and because they were tion systems which are a combination of competitive. stand-alone Signature machines and doublehead systems which combine the Signature with a ferrous-in-foil detector head.

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Tank Scale

High Accuracy Tank Scale Perfectly Rejecting Vibration

Thailands Minor Dairy Limited has recently put into operation a brand new METTLER TOLEDO tank scale assuring reliability and high throughput.

Minor Dairy Limited is a subsidiary of The Minor Food Group a leader in the world of food manufacturing, where in Thailand it holds a market leader position for premium ice cream business, known as SWENSENS. Due to the well-known good taste and great quality of SWENSENS premium ice cream, raw material control is a critical point in order to assure consistency and high throughput of production. Minor Dairy Limited proposed to install a tank scale system to accurately measure raw material used in each batch. The objectives were to achieve a higher level of accuracy than the old system, eliminating vibration caused from production process agitator, and the need to com-

ply with international food regulations such as GMP and HACCP. Minor Dairy Limiteds most important concern was after sales service. The solution for a sensitive production process After demonstrating the benefits of METTLER TOLEDO tank scale components and services, Minor Dairy Limited took the final decision to implement two sets of IP68 protected FlexMount weigh modules with an IND560 process weighing terminal and a Scoreboard (large display module). Additionally, flexible hoses were installed into the existing pipe system ensuring maximum tank scale accuracy one of SWENSENS main requirements.

With its IP69k stainless steel housing, the IND560 weighing terminal is the perfect match for a tank scale process weighing application in the food industry. The extremely high A/D conversion rate of 366 readings per second is combined with proven TraxDSP filtering to make sure that the tank scale consistently provides fast and precise weighing results even in difficult vibrating environments. Mr. Songwut Reongkosum, Factory Engineering Manager, concludes: The METTLER TOLEDO system specialists made a big effort to understand our requirements and met them all to our complete satisfaction. With the service contract we now have the safety we require to run our production smoothly.

Scoreboard large display module

FlexMount weigh module

Dustproof and suitable for cleaning with high-pressure equipment Junction box IND60 process terminal

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Fast facts: IND560 Process weighing terminal Display: Active VFD dot matrix, SmartTrac over/under display Alibi memory Extremely high A/D conversion rate of 366 readings per second TraxDSP supreme noise and vibration filtering Panel-mount and harsh environment versions, IP69k Digital I/0: 12 in/18 out Interfaces: RS232, RS48/422, Profibus DP, DeviceNet, Allen-Bradley RIO, Ethernet, Digital I/O, 4-20mA and 0-10V analog output

TraxDSP is a patented filter design that practically eliminates environmental noise and vibration to provide stable weights.

Protected against submersion

Fast facts: FlexMount weigh module Hermetically sealed stainless steel IP68 load cell the right choice for hygienic sensitive areas Capacity range 110kg 20.4t 3000e OIML, 000d NTEP Top plate rigidly located for easy installation Uplift protection Large range of thermal expansion/contraction possible Stainless steel mounting hardware Global approvals standard on every load cell

Key Benefits for Minor Dairy Limited High accuracy tank scale Accurate results even in difficult environments with vibration Standard regulation compliance as GMP Safety through service contract
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A Wide Range of Solutions to Improve Processes

1. PUA579 Drive-through floor scale 2. BBA449 over/under check scale with colored backlight 3. Garvens S3 SHARK Combiweigher 4. In-line turbidity, pH and conductivity sensors

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Share our Knowledge

Learn from our specialists our knowledge and experience are at your disposal in print or online. Learn more about all of our solutions for the dairy and cheese industry on our website. You can find information on a wide range of topics to improve your processes, including case studies, application stories, return-on investment calculators, plus all the product information you need to make an informed decision.

1. Statistical Quality Control / Statistical Process Control 2. Process weighing 3. Industrial Catalog 4. Product Inspection solutions
GARVENS
Checkweighing

Product Inspection

SAFELINE
Metal Detection & X-ray Inspection

System Integration

Whatever your inspection needs, we can provide either stand-alone or fully integrated bespoke systems to address the challenge.

Product Inspection Solutions

Fully Integrated Solutions tailored to suit your needs

Total Product Inspection Solutions for processing and packaging

Focused on the key aspects of industrial product inspection, the METTLER TOLEDO PI division is the market leader in its field. We are a highly resourced business committed to innovation and new developments, dedicated to serving the needs of our customers by addressing their challenges of today and in the future. As part of a global business we are able to draw on a wealth of industry experience developed by working in true partnership with our customers worldwide.

Market leading global brands

The Garvens and Safeline brands combine to give the most comprehensive product inspection range of equipment with solutions for checkweighing, metal contaminant detection and X-ray inspection.
Checkweighing A part of the METTLER TOLEDO group since 1986, GARVENS is one of the worlds leading manufacturers of dynamic weighing systems. Our systems can ensure 100% quality control and give you total peace of mind. Metal Detection Safeline has long been the undisputed global market leader in metal detection technology. Since joining the METTLER TOLEDO group in 1996, Safeline have continued to dominate this important inspection market sector. X-ray Inspection Since joining the METTLER TOLEDO group in 2002, Safeline X-ray Inspection has rapidly grown its range of innovative solutions using cutting edge X-ray technology. These systems provide the means to detect the broadest ranges of contaminants possible.

Checkweighing Metal Detection X-ray Inspection Service XXL

Solutions for all markets

Experience gained over many years in the broadest range of industries and applications mean that we have an extensive array of solutions and technologies at our disposal. Our product range includes dynamic checkweighers, sophisticated metal contaminant detectors and cutting-edge X-ray based inspection technology. Whatever your processes or industrial sector, we have solutions to benefit your business and maintain your competitive edge.
The food industry We can provide solutions for all packaging and processing aspects of the food industry. Applications include the weighing and inspection of wet, dry, fresh and frozen food stuffs in all food sectors. We can also help your business to comply with legal requirements, industry guidelines and codes of practice including IFS and BRC standards.

GARVENS
Checkweighing

SAFELINE
Metal Detection

SAFELINE
X-ray Inspection

Mettler-Toledo Garvens GmbH Kampstrae 7 D-31180 Giesen Germany Tel: +49 (0)5121 9330 Fax:+49 (0)5121 933 456 Email: garvens@mt.com Mettler-Toledo Safeline Ltd Montford Street Salford, M50 2XD UK Tel: +44 (0)161 848 8636 Fax:+44 (0)161 848 8595 Email: sales@safeline.co.uk

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Breadth of experience, depth of capability for complete product inspection solutions

The pharmaceutical Industry Our solutions for the pharmaceutical industry include weighing and inspection technology for tablets, capsules, powders and insert documentation. We can also provide assistance in meeting the demands of GMP and our equipment is compatible with CFR 21 part 11 requirements.
The cosmetic and chemical industries We can provide solutions for the inspection, weighing and sorting of products from bulk liquid, powder and granular chemicals through to small consumer packs such as healthcare products, toothpastes, lotions and detergents.

Unrivalled connectivity options...

The full range of METTLER TOLEDO PI products can be further integrated using state of the art communications software packages facilitating greater control and traceability in all of your processes. Equipment is compatible with METTLER TOLEDOs innovative FreeWeigh. net package, Safeline Explorer and the GARVENS ReAcT systems. In addition, all equipment can be linked to a wide range of other market leading data acquisition or factory management/SCADA systems such as InTouch, RSView, Intellution and Matrikon.

Mettler-Toledo Safeline X-ray Ltd Greenfield, Royston Business Park Royston, Herts SG8 5HN UK Tel: +44 (0)1763 25 7900 Fax:+44 (0)1763 25 7909 Email: sales@safelinexray.co.uk

Subject to technical changes Mettler-Toledo PI Printed in UK MTPI-UKPO-PICBE-0506-1M

Non-food and non-pharma industries Our solutions can also be applied to a wide range of other applications including inspection in paper converting, textiles and component manufacture. We can also provide systems to determine piece count by weight, for example, nuts and bolts for D.I.Y markets and the weighing and rejection of out-of-tolerance coin blanks prior to embossing.

Mettler-Toledo AG CH-8606 Greifensee Switzerland Tel. + 41 44 944 22 11 Fax + 41 44 944 30 60 Your METTLER TOLEDO contact:

www.mt.com/dairy-cheese
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