News. Specialty Chemicals. Efficient filling process Are we fast enough for you? Industrial Weighing and Measuring

Transcription

1 Specialty Chemicals Industrial Weighing and Measuring 7 News Efficient filling process Are we fast enough for you? To keep up with market demand, the Chemical Industry is required to continuously increase operation efficiency and speed. The IND560 weighing indicator empowers you to increase speed during filling steps while keeping accuracy and reliability. Efficient filling with the highest accuracy The new IND560 not only gives you the capability to perform accurately different weighing applications such as blending and filling or inventory control. But it also enhances the reliability of the system resulting in an increase in productivity. The features of the new IND560 add key benefits to your process and help you achieve highest product quality. Simple operation for increased productivity The Fill-560 application software module allows prompt configuration of standard or customizable sequences for filling, blending, dosing and discharging SmartTrac graphical guidance for target weight and tolerances helps the operator reach the fill target faster CalFREE is the smart and simple way for electronic calibration without test weights Quick configuration with InSite Software. Connected to the IND560 indicator or off-line, the software allows smooth changes to setup and configuration parameters High reliability and accuracy MinWeigh function ensures all measurements are within the tolerances of your weighing processes Calibration management monitors system performance and alerts operators of potential failures or maintenance needs for maximum uptime TraxDSP filtering system provides accurate weighing even in unstable environments Courtesy Clariant

2 2 Fomulation solutions Publisher Mettler-Toledo AG Industrial Heuwinkelstrasse CH-8606 Nänikon Switzerland Production MarCom Industrial CH-8606 Nänikon Switzerland Looking for a concrete solution? Formulating specialty concrete with high precision For the construction of structures subjected to cyclic loadings as bridge decks, highway roads, runways of airport and buildings the demand for high resistance concrete is increasing. The accurate dosing of metallic fibers into the concrete s cementitious matrix is fundamental to ensure proper resistance of the structure. Our customer Dalaudière Franken is a specialist in this field. Concrete is a material that is strong in compression, but very weak in tension, as the cement holding the aggregate in place can snap, allowing the structure to fail. Using reinforced concrete solves these problems by adding, amongst other things, metallic fibers to carry tensile loads. The regular dispersion of the metallic fibers into the cementitious matrix is very important to ensure the high quality of the concrete and to guarantee the maximum safety of the structure. However, the dosing of metallic fibers into the concrete is not easy since the metallic fibers tend to stick to each other. The best solution is to Subject to technical changes 07/2008 Mettler-Toledo AG Printed in Switzerland METTLER TOLEDO Specialty Chemicals News 7 use vibrating equipment which will keep the fibers apart whilst dosing them into the concrete. Courtesy Dalaudière Franken Founded in 1875, our customer, the company Dalaudière Franken, is specialized in the realization of vibrating components and machinery based on the use of electromagnetic and mechanical technologies. Dalaudière Franken provides plug and play set-ups for many different industries. In this case study we look at a solution proposed by Dalaudière Franken to one of the major French concrete manufacturers. High precision dosing, enhanced productivity and improved traceability are added values brought by Dalaudière Franken in the proposed solution. Embedded in Dalaudière Franken equipment are instruments and weighing solutions from METTLER TOLEDO. Embedded in Dalaudière Franken equipment, the METTLER TOLEDO weighing terminal IND690 and scale guarantee the accurate dosing of metallic fibers.

3 Weighing precisely under vibration? No problem! The Dramix metallic fibers are discharged into a turning vessel of 1300 lts capacity. From here they are fed slowly into a vibrating bowl of 20 lts capacity. In the bowl the fibers are separated and regularly fed into a small basin. The basin is placed on a METTLER TOLEDO PBA scale. Dramix metallic fibers in the weighing range of kg are weighed in the basin every 3 minutes, and then fed onto a moving belt. The Dramix metallic fibers are finally dosed into the kneader used for concrete production. The engineers at Dalaudière Franken have created a smart solution that totally uncouples the vibrating bowl from the weighing instrument. Thus avoiding any influence of vibrations on the weighing operation. Furthermore the full dosing operation is managed by a METTLER TOLEDO weighing indicator IND690. The equipment from METTLER TOLEDO integrated into the solution guarantees extremely accurate and reliable weight control of the fibers within a range of +/- 60 g, even at enhanced speed. When? How? How much? Transparency of information and full traceability of production are easy! The IND690 can record recipes by assigning charge, lot, and batch, and keep track of all weighing operations. The weighing indicator facilitates the handling of recipes with less paper production. This results in higher production efficiency. The solution has allowed Dalaudière Franken to realize a set-up which minimizes material losses, maximizes productivity whilst ensuring high product quality. This has fully satisfied the expectations and requests of the concrete manufacturer, who is going to install the same kind of solution in other production sites. Courtesy Dalaudière Franken IND690 Up to four scales/balances connectable Water and dust-proof Wide variety of software Pacs such as Count, Form, Com, Sum, Fill, Batch, Control, FormXP Broad interface range available: Ethernet, WLAN, USB, Bluetooth, Profibus DP Material identification through barcode reader and RFID PBA430 bench and floor scales Stainless steel design, IP68/69k protection Capacity: from 3 kg up to 600 kg Resolution: e multi-range The solution created by the engineers at Dalaudière Franken uncouples the vibrating bowl from the weighing instrument for extremely precise weighing operations. METTLER TOLEDO Specialty Chemicals News 7 3

4 4 Networked formulation solutions Fail-proof dispensing and formulating? it sounds good and it tastes even better! Lucta manufacturing site in Barcelona covers all production steps for both natural and synthetic flavors. Lucta masters more than 200 different chemical reactions for a production of 1200 tons of chemical essences per year, used for the in-house formulation of flavors. Established in 1949 Lucta is an international company manufacturing human flavors, fragrances and feed additives. The human flavors are divided into savoury flavors for meat products and snacks and sweet flavors for confectionary, dairy and bakery products. METTLER TOLEDO Specialty Chemicals News 7 The manufacturing of flavors is a rather complex process that starts with the synthesis of chemical essences through more than 200 different chemical reactions to produce thousands of different aromas. These are further formulated and mixed to obtain the final flavor product. Powder and liquid aromas, oils, preservatives, ph modifiers, solvents and many other additives are the main ingredients of a flavor. These represent a large number of raw materials that need to be dosed consecutively. A proprietary software solution from METTLER TOLEDO ensures fail-proof management of powder formulations. For daily production, the recipe is directly downloaded to the industrial PC ID30. The METTLER TOLEDO weighing management software integrated in the terminal controls the communication with the customer s ERP. The ingredients are identified by barcode and weighed in one of the two METTLER TOLEDO platforms connected a high precision KCC with 300 kg capacity and a PBA430 with 30 kg capacity. The software guides operators with useful information about raw materials handling and weighing procedures throughout the weighing process. The ERP integrated solution provides realtime data for material management purposes, e.g. remaining stock volume and expiration date. The ID30 user-friendly screen shows graphically the target and tolerance range for accurate and failproof operations. Additionally the software records and documents automatically all relevant information as requested for a process fully in compliance with cgmp/ GAMP and 21 CFR part 11. The weighed raw materials are finally identified with a barcode and transferred from the weighing booth to the mixers in the production area for the final flavor formulation. Courtesy Lucta

5 SAP Production Planning PP-PI Module (PCS interface) Download bill of materials after order release in the ERP FormWeigh.Net Server Dispensing system Upload consumtion data for stock adjustment FormWeigh.Net is a software-based formulation solution for batch manufacturing. It consists of a weighing terminal, a variety of weighing platforms, a barcode reader and a printer, and can be configured to match your individual needs. The networked solution offers the advantages of central data management, full integration with your ERP system, and full traceable paper-free formulation. Warehouse and recipes management Process specifications measure and control; raw materials identification Accuracy Reliability Compliance Raw material weighing (upt to three scales or balances) KCC330/s PBA430-B30 XS6002s Electronic batch documentation, 21 CFR Part 11 compliant All relevant batch information and the operator s signature are electronically documented. Protected access guarantees that sensitive data can only be seen and/or changed by the authorized people. The functions implemented into FormWeigh.Net ensure full GMP compliance with FDA s 21 CFR Part 11. Secure process with unique labeling system Every raw material is identified uniquely with a barcode. FormWeigh.Net recognizes the raw material by reading the barcode with a laser scanner, verifies its quality status and the expiry date. The material information displayed helps operators to prepare the right ingredients for the batch. Furthermore, safety precautions and handling procedures are highlighted on the screen. FormWeigh.Net confirms that each quantity is correct before the operator is allowed to start weighing. Order overview: select your recipe and start weighing An easy-to-read order list is displayed and the system is ready for production. The weighing of the required raw material can be started by simple selection. Visualization of the weight FormWeigh.Net shows you graphically and numerically how far you are from the target weight. The required tolerances are clearly displayed as limits and weighing results that exceed or fall below these limits are shown in different colors. This helps to highlight potential problems and prevent mistakes. ID30 user-friendly touchscreen flat panel The operators select or place the order directly at the weighing station and control it simply with a light touch of the screen. Efficient system validation METTLER TOLEDO offers proven bestpractice validation manuals and consulting support for seamless and effective validation of FormWeigh.Net system in compliance with GAMP 4 guidelines. Weigh and control at your finger tips with the ID30 industrial PC: a weight within the target limits is shown with green bars. METTLER TOLEDO Specialty Chemicals News 7

6 Hazardous area New weighing terminal for use in hazardous areas The new IND226x weighing terminal can be used worldwide by the chemical industry thanks to a wide range of approvals. Users benefit from a number of functionalities and application options. Approvals International guidelines permit the ergonomic IND226x to be used in the hazardous area of zone 1/21. OIML and NTEP metrological approvals and international Ex certifications allow global usage. The IP66-protected stainless steel housing can withstand the toughest operating and cleaning conditions and is therefore the ideal solution for weighing applications in harsh industrial environments. Master Interface IND Interface Remote OR System configuration Hazardous Area Safe Area OR ACM200 IND690 Functionality With its 7-segment LED display, the integrated over/under control weighing mode ensures exact container filling. Further functions, such as MinWeigh which ensures weighing is always carried out within acceptable limits, and CalFREE, which allows electronic calibration on weighing modules, provide the industry with simple handling and effortless processing. Another advantage of the terminal is its compatibility with all METTLER TOLEDO analog weighing platforms. Remote Application options With the mountable IND serial data interface and the ACM200 interface converter, peripheral devices such as PCs or printers can be connected via an RS232 interface in a safe area. Alternatively, in hazardous areas an additional IND226x can be connected as a remote display via the serial remote interface. Thanks to its various power supply options, the terminal can be used in the widest range of application areas, for example for mobile weighing operations via a mains-free rechargeable battery, for PC Battery pack PSUx an uninterrupted operating time of up to 70 hours. The IND226x offers optimum weighing for the chemical industry. The simple and easy-to-use user interface has been designed with users in mind. 6 METTLER TOLEDO Specialty Chemicals News 7

7 Highly sensitive metal detector helps set standards for the future A UK manufacturer of personal care wipes and tissue based products has recently installed a product inspection system incorporating a METTLER TOLEDO SAFELINE R-Series metal detector. As an integrated part of a fully automated conveyorised system, the detector is capable of locating all types of metal contamination in toilet roll and kitchen towel products. Re-defining standards The decision to install the new inspection system came as a result of a major review of quality control procedures and the redefining of internal factory standards for metal contaminant detection. METTLER TOLEDO was able to give advice on the development of the new metal detection programme which included a full hazard analysis as part of the company s HACCP programme. The system was installed at the final point of inspection immediately after the poly wrapping process and before despatch to the customer to ensure that opportunities for further contamination are minimised. The inspection system has been designated as a critical control point (CCP) for the processing line. needs. After the extensive evaluation of several potential suppliers, the decision was made to invest in the new detector from METTLER TOLEDO. We believe the detector will provide the sensitivity required to enable us to detect the smallest metal contaminants he concluded. A demanding application The industry norm is to run paper converting machines at very high speeds. This can be a punishing environment for cutting blades and converting equipment. Instances of metal contamination can occur as a result of the breakdown of perforation blades and log saw blades. The R Series detector installed utilises high frequency coil technology combined with enhanced electronic filtering techniques. This provides unparalleled online sensitivity to all metal types enabling the detector to identify the smallest metal contaminants. Products with metal contamination are effectively removed from the production line when detected using a fully automated punch reject system which pushes the product into a secure reject bin without stopping the line enabling investigation into the cause of contamination to take place. The smallest contaminants We have used metal detectors as part of our quality procedures for many years but the previously installed detector could no longer consistently meet the new standard we set as part of our programme commented the production manager. The welfare of our customers and exceeding our quality standards are critical to the future of our business and we had to look for a new system which could meet our METTLER TOLEDO Specialty Chemicals News 7 7

8 High-precision weighing in automated processes If the preparation and dosing of harmful substances is done manually under a cabinet, this could potentially expose the operator to the dangerous substances. Our solutions allow to protect operators and guarantee the maximum accuracy as well as high product quality for your end-users. Efficient compounding with the highest accuracy and safety Harmful components must be fully contained during their processing in order to minimize operator exposure and to avoid cross-contamination. Filling and dosing applications as well as simple weighing of toxic or dangerous compounds must be carried out in proper containment equipment to eliminate any handling risks and ensure maximum operator and environmental protection. Embedded into the containment equipment, e.g. glove boxes Courtesy Howorth Pharma and/or weighing robots, the METTLER TOLEDO WM weighing modules are specifically designed for use in automated processes under every industrial environmental condition. The main feature of METTLER TOLEDO s WM3002 high-precision sensor is its ability to measure from few kg down to the milligram range in a fraction of a second. Complex algorithms for digital noise filtering ensure qualified weighing even in the presence of vibrations. The compounding time is further optimized thanks to highspeed digital data processing and direct data transfer over RS232 or RS422 to a PLC. The weighing sensor can be serviced on site and easily calibrated by means of its internal calibration device or with external weights. WM weigh modules/weigh sensors Capacity: from 120 g/0.1 mg up to 6 kg/10 mg Internal calibration device ATEX: Zone 1 or 2 FM: Division 1 Wash down option IP66 Very compact Fast update rate of 38 Hz Stainless steel housing (316L) with smooth surface With optionary accessory module: RS232/RS422 DeviceNet Profibus DP Ethernet SIWAREX FTA Mettler-Toledo AG CH-8606 Greifensee Switzerland Tel Fax Your METTLER TOLEDO contact: For more information