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Proprietary & Confidential
Checkweigher Principles

2 Proprietary & Confidential
Topics for Checkweigher Training
• THE BASICS:
• Introduction
• Principles of Checkweighing
• Reasons for Checkweighing
• A Practical Guide to Checkweighing
• Thermo Products
• Company History
• Key Checkweigher suppliers world-wide
• Applications Examples and Discussion
• RFQ, Quotations, and Price Book understanding CW selection,
features and options

Principles of Checkweighing
• What is a checkweigher?
+

• Scale + Person
• Put product on scale
• Wait for scale display to stabilize
• Compare weight to known limits
• Remove product from scale
• Discard, or Keep
Can you do all
this in 1/10th
second?

• Checkweigher
• Conveyor moves product onto scale area
• Photo-eye tells the computer that product is arriving to be weighed
• Computer waits for scale to stabilize
• Computer calculates weight, compares to known limits
• Conveyor move product off scale
• Computer activates reject device if necessary

• Essentially two sub-categories
• Intermittent motion
• Package is stationary when weighed
• Typically slower, more mechanically complex and more accurate.
• Not common today outside Weigh Price Labelers
• Continuous motion
• Today’s topic...

• Generally four elements to a checkweigher:
• Conveyor system
• Weighing transducer (loadcell)
• Control system
• Reject device
• (Go into Demo room to look at checkweighers for 20 minutes)

• Drag-link, or Chain, conveyor
Pack
Loadcell
Photo-eye
Flow
Plastic or metal chains
are pulled across
checkweigher...
…by a large motor
beneath the
system.
Weighing
zone

• Drag-link, Slack Belt, or Chain conveyor
• Robust, simple, low maintenance
• Fast; up to 600ppm
• Subject to inaccuracy from chain noise
• Only for solid and packaged products
• Generally medium accuracy potential
• Ramsey: FR8120C

• Powered Weigh Platform conveyor
Pack
Photo-eye
Flow
Weighing
zone
Loadcell
Individual miniature motors
drive small balanced flat belt or
round belt conveyors separately

• Powered Weigh Platform conveyor
• Flat belt or round/o-ring belts
• Higher maintenance requirement
• Good for flexible and difficult to handle products,
including unwrapped
• Generally high accuracy potential
• Slower (more mass on loadcell)
• Subject to inaccuracy if noise in
conveyor transmission
• Ramsey: VersaWeigh, Versa Flex
• FR44HB, RxPWT

Checkweigher Configuration
• Weighing transducers:
• LVDT -- no longer in common use,
some older checkweighers may still use though.
• Many moving parts, robust but set-up is critical.
• Load Cell -- most common device today.
• aka ‘Strain gauge’
• Simple, standard off the shelf device
• Fast but subject to overload and drift
• Digital load cell
• Ramsey products all use strain gauge load cells

• 3 zone vs. 5 zone operation
+15g
-15g
+15g
-15g
Target
-100g
Under Rejects
Over Rejects
Under Rejects
Gross Under Rejects
Over Rejects
Accepts, slightly heavy
Accepts, slightly light
Gross Over Rejects
+100g
Target
Accepts, slightly heavy
Accepts, slightly light

• Reject Devices
• Many available; selection dependent on application. Considerations:
• Speed/reaction time
• Vibration
• Available space
• Package/product type
• Local preference
Choices?
Pusher
Air-blast
Sweep-arm
Diverter
Lift/drop flap
Channelizer

Checkweigher Configuration

• The Weighing Process…package approaching
Pack position:
Loadcell output:
zero
Pack weight
Pack
Photo-eye

• The Weighing Process…package entering
Pack position:
Loadcell output:
zero
Pack weight
Pack
Photo-eye

• The Weighing Process…package almost on
Pack position:
Loadcell output:
zero
Pack weight
Pack
Photo-eye

• The Weighing Process…package completely on
Pack position:
Loadcell output:
zero
Pack weight
Pack
Pack settling
Photo-eye

• The Weighing Process…package on
Pack position:
Loadcell output:
zero
Pack weight
Pack
Pack weighing
Settling time
Photo-eye
Settling time is
typically around
50mS.

• The Weighing Process…package on
Pack position:
Loadcell output:
zero
Pack weight
Pack
Pack weighing
Photo-eye

• The Weighing Process…package leaving
Pack position:
Loadcell output:
zero
Pack weight
Pack
Weighing time
Photo-eye

• The Weighing Process…package off
Pack position:
Loadcell output:
zero
Pack weight
Pack
Photo-eye

• The Weighing Process…package gone
Pack position:
Loadcell output:
zero
Pack weight
Pack
Photo-eye

• The Weighing Process…automatic zero
Pack position:
Loadcell output:
zero
Pack weight
Pack
Photo-eye
Auto zero activity Auto zero activity

The Weighing Process
• Close up on weighing time
Pack position:
Loadcell output:
zero
Pack weight
Pack
Weighing time
Photo-eye

• Weighing Time + Settling Time=Data Acquisition Time
• The difference between the weigh-table length and the pack length
determines the weighing time. System must settle, and take weight
values during this time.
• The longer the weighing time, generally the more accurate the system.
Weighing time = (weigh-table length - pack length)
(belt speed(FPM) / 5)
Pack

• Weighing time (recommended)
• Versa Control
• FR8120C (Cans): 0.060 sec.
• FR8120C (Cartons/Bags): 0.100 sec.
• VersaWeigh: 0.120 sec.
• FR44HB: 0.250 sec.
• Rx (Slack Belt): 0.060 sec.
• Rx (PWT): 0.120 sec.
• Teorema: 0.030 sec.

• Ideal spacing, allows a zeroing operation (A/Z) between each pack
• Maximum accuracy, but limited throughput
zero
Pack weight
Pack Pack
Pack
A/Z A/Z
A/Z

• Critical spacing; no on-going auto-zero activity
• More throughput, but borderline integrity. An A/Z must occur sometimes!
The minimum time is set as an alarm
zero
Pack weight
Pack Pack
Pack Pack

• Packs too close. Result: 1st pack is weighed heavy
zero
Pack weight
Pack
Pack
Weighing time

Accuracy/Repeatability

• Four key areas for attention
• Accuracy
• Meaning
• Testing for
• Faultfinding
• Calibration

• Accuracy
• Many different ways to calculate
• Two different “accuracy” measures:
• Variability/repeatability -- how much might the displayed weight vary
for a fixed (specific) weight pack.
• Absolute Accuracy/Systematic error -- how close is the average of
displayed weights to the actual weight of a pack.

• Good repeatability, bad accuracy (high systematic error)

• Good accuracy, poor repeatability (but low systematic error)

• Good accuracy and repeatability

• Bad accuracy and repeatability

• Measurement of Variability/Repeatability
• Standard deviation n: a measure of dispersion in a set of data
© Merriam-Webster, Incorporated
• If a measuring device was ‘perfect’, then multiple measurements of the
same item would be identical, and the standard deviation would be zero.
• 16.05, 16.00, 15.93, 16.10, 15.91, 16.10, 16.08, 15.95
 Standard deviation = 0.0780
• 16.00, 16.01, 15.99, 16.00, 16.00, 16.01, 15.99, 15.99
 Standard deviation = 0.0083
• …but all the readings could be wrong (systematic error)!
• 15.00, 15.01, 14.99, 15.00, 15.00, 15.01, 14.99, 14.99
 Standard deviation = 0.0083 (good SD, bad average error)

• Example accuracy test on a Versaweigh
• 20 passes of a single pack
• Actual test pack weight: 297.4g
 Average = 298.6g (absolute error = + 1.2g)
 Range = 1.1g (= ± 0.55g?)
 Standard deviation = 0.3g (= ± 0.6g? …or ± 0.9g)
298.5g 298.4g 298.3g 298.9g
299.1g 298.8g 299.0g 298.8g
298.6g 298.0g 298.5g 298.5g
298.7g 298.1g 298.3g 298.2g
298.4g 298.8g 298.7g 298.5g

Calibration-Dynamic
• Frequency of re-calibration:
• Once/shift, or once/day
• Every time pack to be run changes
• When testing shows systematic error
• Challenges
• Never perform during production run
• Always pass pack with great care
• Ensure ‘standard’ pack weight hasn’t changed

Reasons For Checkweighing

Reasons for Checkweighing
• Enhance consumer satisfaction
• Ensure legal weight compliance
• Ensure compliance with label statements
• Enhance plant efficiencies

• Enhance consumer satisfaction:
• Eliminate under & over weights
• Functional products
 Toppings
• Flavor or salt level
• Adequate or inadequate amount
 Cakes
• Ratio against added ingredients
 Popcorn
• Amount factors into bag size and microwave energy

• Enhance consumer satisfaction:
• Eliminate short counts/missing components
• Multi-component meals/desserts - failure
• Snacks - disappointment

• Ensure legal weight compliance
• NIST Handbook 133 “Checking the Net Contents of Packaged
Goods” defines compliance:
• Average of lot equals declared weight
• No unreasonable short weights (no packs short by more than
the MAV)
 MAV = Maximum Allowable Variation
• Prior to 2002, H-133 used to state specific Checkweigher
requirement; but no more
• “..If a packager uses checkweighers, not only must the average of
the lot equal (or exceed) the label, but under no circumstance
should the checkweigher accept packages that are short measure by
more than the MAV.”
Handbook 133, 3rd edition, section 1.6.1

APractical Guide to
Checkweighing and Checkweighers

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Overview
What Is a Checkweigher?......................................................04
Why Use Checkweighers: Brand Security........................ 05
Why Use Checkweighers: Regulations..............................06
Why Use Checkweighers: Plant Efficiency........................07
Why Use Checkweighers: Weight Control........................08
Technology
Three Sections of a Checkweigher Frame..................... 11
How It Weighs.......................................................................12
Moving Objects Along.........................................................13
Rejecting Products...............................................................14
Why is Weighing Accuracy Important?............................15
How to Keep Checkweighers in Top Performance.........17
Checkweigher Do’s and Don’ts........................................ 19
Package Types......................................................................20
Customization.......................................................................21
Benefits of Multi-Lane Checkweigher Solutions........... 22
Meeting IP65 Washdown Requirements.........................23
Equipment
Versa Flex Checkweighers...........................................................25
Global VersaWeigh™
Checkweighers..........................................26
Versa 8120 Chain Checkweighers..............................................27
Versa Rx & Versa RxV Pharmaceutical Checkweighers........28
VersaTeorema,VersaFrame44,andGlobalVersaCheckweighers..29
Combine a Checkweigher with a Metal Detector...................... 30
Combine a Checkweigher with X-Ray Inspection..................... 31
Is Your Checkweigher Up to Date?............................................... 32
Choose the System That’s Right for You.....................................34
table of contents
4

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Package Types
Types of items that can be weighed on a checkweigher:
• Rigid (cans, cardboard packages, plastic, glass)
• Soft (plastic, paper, foil)
• Wet (dairy, hummus)
• Dry (rice, oatmeal)
• Raw (chicken, beef, fish, vegetables and fruits)
Both food and non-food packages can be weighed on checkweighers: pharma, personal care
packaged items, bullets, bags of construction materials like cement, salt, etc.
technology
Contact
us
›
thermofisher.com/checkweigher

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Combine a Checkweigher with a Metal Detector
Metal detection systems provide reliable, cost-effective protection from even the smallest metal
contaminants found anywhere in a food production process. They can also help improve
operational efficiency and eliminate expensive downtime, service costs and repair bills. There are
many uniquely designed metal detectors suited for a wide range of demanding food processing
and packaging environments.
Continue ›
Thermo Scientific™
Sentinel™
Multiscan Metal Detector
Product details ›
Thermo Scientific™
APEX 500
High Performance Metal Detector.
Product details ›
equipment
Contact
us
›
51

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Combine a Checkweigher with X-Ray Inspection
X-ray inspection systems provide protection from metal, glass, stone and other dense foreign
objects for most any type of packaged, bulk, or piped product.
Find metallic and non-metallic foreign objects and eliminate “wet”
product effects common with metal detectors with the Thermo
Scientific™
NextGuard™
X-ray Detection Systems. Designed
for a wide variety of food applications, NextGuard systems offer
enhanced capabilities to inspect packaged products for missing pieces
or components, under and over-fills,and other quality problems with
easily customizable vision software. Both the C330 and C500 models
are easy-to-use, cost effective and thoughtfully designed systems that
eliminate common barriers when migrating from metal detection to X-ray
inspection.
Product details ›
equipment
Contact
us
›
thermofisher.
52

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Package Weight Range 10g–3kg; 6kg
Versa Flex,
Versa Flex GP
Versa 8120 VersaRx
Global VersaWeigh,
Global Versa GP
up to 0.125g up to 0.5g up to 0.125g up to 50mg
Medium High Medium
Medium
Med-High
Med-High
35g–11kg 10g–3kg or 10kg
2g–300g (slack);
10g–500g (PWT)
Max Product Rate (high 500–
700+ per min; medium 250–
500 per min; low 50–250 per
min)
Accuracy (Standard Deviation per
R51/Handbook 44 Equiv.)Actual
results dependent on line speed,
package material/fill/weight, and
handling
Max Line Speed (high120m/393
ft per/min+; medium 60m/196
ft to 120m/393 ft per min; low
10m/33 ft to 60m/196 ft permin)
Choose the System That’s Right for You
equipment
Contact
us
›
Medium High
Click here to access the full
product selection guide
thermofisher.
53

Thermo Scientific Products

VersaWeigh Powered Weightable
• Available in four belt widths 140, 200,
300 and 400 mm
• Three roller diameters 16, 24, 34 and
42 mm available in aluminum and SS
• Three brushless motor sizes 100, 200
and 400 Watt
• IP55 and IP66 protection level
• OIML and MID approval (European
Weight and Measures)
• Powered Weightable Conveyor
(supplied in many sizes)
• Products: bags, cartons, etc.
• Applications: 25g up to 10kg.
• Combo version ( with metal detector)
available

Versa Flex Powered Weightable
• Available in four belt widths 140, 200,
300 and 400 mm
• Three roller diameters 16, 24, 34 and
42 mm available in aluminum and SS
• Three brushless motor sizes 100, 200
and 400 Watt
• OIML and MID approval (European
Weight and Measures)
• Combo version ( with metal detector)
available
• Standard 3 motors only; no
freestanding infeeds

GP Powered Weightable
• Weigh table available with two belt
widths: 140, 200 mm
• Three roller diameters 16mm and
27mm, available in aluminum and
SS
• Two brushless motor sizes 100,
200
• OIML and MID approval
• Combo version available

FR8120 Chain Weigh frame
• Workhorse for a wide range of pkgs
• Conventional chain design
• Fast (to 700ppm)
• Easy to maintain
• Durable
• Easy to reconfigure
• Ideal for contract packers
• Broadest range of product
characteristics.
• Washdown option for the harshest
of environments.
• Combo version available
System in photo shown with belt in/outfeeds;
can be chain or intralox)

Frame 44 Heavyweight
• More than just a ‘box-weigher’
• Cases, bags, large packages
• Four-loadcell configuration
provides exceptional range,
performance and robust
characteristics.
• Weightable standards 18” or 24”
belt width; length 33” to 87”

Teorema Canning Checkweigher
• Specialty product – for open or closed cans
• No exact competitor –slide weight table)
• High rates to 700+/min
• High accuracy to ± 0.5g
• No chains on weigh-table…reduced maintenance

Teorema – Guarding for safety
•Fully guarded and
interlocked with
cage-style
enclosure
prohibiting access
to moving parts (to
European
standards).

Teorema System

Teorema Canning Checkweigher
• Standard features
• Includes Infeed, Weigh-section, Outfeed
• Infeed/outfeed chains or ULTOP plastic belting
• Infeed/outfeed are free-standing
• Includes reject device (bopper or flipper)
• Central point of lubrication for bearings
• Feedscrew
• Can-stop
• Side-to-side transfer, infeed & outfeed

Wormscrew, Helix
Used to control pitch

Side Belts Transfer
Heavy Duty Side Belt Transfer,
FR8120C
Side Belt Transfer,
Rx, GP and VersaWeigh
Used to allow smooth transfer onto and off of checkweigher

Checkweigher Controls
• Control Systems
• Can be free-standing or fixed to conveyor
system
• Can be simple or complex
• All microprocessor based

Checkweigher Controls
• Versa
• Up to 700 cpm
• 100 product memory, expandable to
400
• Windows Based, 10.4” (diagonal)
high resolution color user touch
screen interface
• Multi-diagnostics and accuracy test
displays
• Multi-statistics displays
• Highly customizable user interface.
• R51 Approved in many countries
• 15 languages

Checkweigher Control Options
• Control features available; standard
• No-gap detection
• Pack Too Long (skew) detection
• Three or Five zone operation
• Multi-level password protection
• Auto-zero failure detection
• Checkweigher activity logs
• Automatic product changeover

• Control features available; data reporting
• Zone counters
• Data communication to PC
• EtherNet – FTP
• EtherNet – Modbus IP
• EtherNet Tunnelling
• Serial - RS422
 Individual Package Weights
 Formatted Reports
• Fault/Error reporting
• Basic Statistics
• Expanded Statistics; histogram, X-R charting

• Example (Versa) expanded
statistics report

• Example (Versa) histogram (bell curve) report

• Control features available; options
• Reject verification
• Reject bin-full detection
• Failsafe
• Consecutive reject detection
• Low air pressure detection
• Integration with other sensors
• Servo feedback to filler
• 21 CFR Part 11
• Tracker operation

• Servo (Filler Feedback Control)
• Pulsed Output
• Provides two separate outputs, one for increase, one for decrease
 Adjustable correction pulse length
 Adjustable correction limits
 Adjustable average count
 Adjustable startup count
• Serial Output (RS232)
• Individual package weights
• Filler uses these weights and has control feature in it’s electronics

• 21 CFR Part 11
• Comply with FDA guidelines
• Security Device for electronic audit trails
• Equipped with an internal hard drive
• Stores Records
• Stores Events
• Stores User Information

Versa Flex/ Versa GP Software release V100

Competitor Review Summary
• 3 conveyor belt checkweigher
• Many manufacturers (over 50)
• Main competitors have Flex offering
• OCS Essential $15k(USA) (11k Euro)
• MT XC3 $15k(USA)
• Local Chinese $6k~10k for export
• [Note: Prices above are ~2013 prices, add 5-7% for 2016]
• Spot and volume discounting another 10% to retain market
share is common
$16750
Versa Flex
IP54
100
250

Price Book Review

Company History

Company Checkweigher History
• Icore – California- first checkweighers produced as Illuminatronics
• Ramsey Engineering – MN
• Ramsey Technology – MN
• Tecno Europa – Italy
• Best Checkweigher’s - England
• Thermo Sentron – MN
• Thermo Electron – MN, Italy
• Thermo Fisher Scientific – MN, Italy, China
Names from the past

Checkweigher Suppliers

Checkweigher Suppliers
• Who supplies them?
• Tier 1 manufacturers:
• Thermo Fisher (Ramsey/Goring Kerr)
• Mettler-Toledo (HiSpeed, Garvens, Safeline)
• Ishida (Heat & Control)
• Tier 2:
• Loma/Cintex • Yamato
• Anritsu • Allfill
• Lock • Thomson Scale
• Weigh-Tronix • Optima (OCS)
• Brapenta

Competitor Comparison
COMPETITOR VersaWeigh
OCS
(Avery)
Garvens Hi-Speed Sartorius Ishida Anritsu Loma
Feature/Model 300 EC/HC X2/3; S2/3
Cornerstone
XE/XS
SYNUS DACS-Z SVf LCW
Manufacturing Location China Germany Germany Ithaca, NY Germany Japan Japan Chicago, IL
Screen size 10.4" not reported 5.7"/10.4" 5.7"/15" 6.4"/10.4"/15" 12.1" 10.4" not reported
Rating (std/optional) IP65/IP66 IP54/IP65 IP54/IP65 IP54/IP65 & IP69k IP54/IP65 IP30 IP66 IP55/IP66
Technology LCD LCD QVGA QVGA LCD LCD LCD not reported
Color Yes No/Yes Yes N/A Yes Yes Yes Yes
Windows XP No No N/A No XP OS "PC Based"
Touchscreen Yes Yes Yes N/A No Yes Yes Yes
Zones (std/optional) 3/5 not reported 5/7 3/5 & 7 3/5 not reported not reported 3/5
Product Memory 100/400 25/500 100/200 100/200 & 400 200 100 50/100 240
Approvals
CE low voltage
directive, CE
machinery safety
directive, CSAUS,
not reported
CE Declaration of
Conformity; ISO 9001
UL/cUL; ANSI
B155.1-1994
EU directive
178/2002; EC
directive
89/392/EEC
not reported not reported OIML R51
Operating Temp Range 0-40 Deg C 5-40 Deg C 0-40 Deg C 0-40 Deg C 0-40 Deg C 0-40 Deg C not reported not reported
WEIGH FRAME
Max capacity up to 10 kg up to 15 kg 600g/6kg up to 7 kg up to 7 kg up to 1.2 kg not reported up to 6 kg
Accuracy @ 2sigma +/- 0.01% from +/- 60mg from +/- 100 mg from +/- 150 mg +/- 0.01g +/- 0.02g +/- 0.20g 0.6g
Weighing technology load cell EMFR EMFR load cell EMC load cell load cell load cell
Line Speed up to 394 fpm up to 400 ppm up to 200 ppm up to 350 fpm up to 300 ppm
up to 120
m/min
105 m/min (>1.2kg)
91 m/min (<3 kg)
up to 250 ppm
Rollers (std/optional) AL/304SS not reported AL 304 SS not reported not reported not reported not reported
Frame (material/finish) 304 SS/4b not reported AL CS or 304 SS not reported not reported 304 SS 304 SS/bead blast
Electrical Enclosure
(material/finish)
304 SS/4b not reported 304 SS 304 SS Stainless steel not reported not reported 304 SS/bead blast
Conveyor Bed
(material/finish)
304 SS/4b not reported AL 304 SS
polished AL
sections
not reported not reported not reported
Load Cell (std/optional) AL/304SS not reported not reported 304 SS 304 SS housing not reported not reported not reported
Motor rating 100-400W not reported not reported not reported 24 V not reported not reported 90W
Belting (std/optional) Urethane (green)/FDA not reported not reported flat (food quality) not reported not reported not reported flat (food quality)
Belt Widths (mm) 100/200/300/400 120 100/120/150/200 100/200/300/400 40-160
100/150/220/
300
not reported 200/250/500
Combo available Yes Yes Yes Yes not reported Yes Yes Yes

Questions?
• www.thermofisher.com/productinspection

Thermo Scientific Checkweiger STANDARD PRODUCTS: Summary
• VersaWeigh Powered Weigh Table Conveyor on frame construction (in many sizes)
• Products: all; bags, cartons, containers etc.
• Applications: all; 25g up to 25kg. IP 66 option.
• Versa GP PWT Conveyor with cantilever construction mounted on cabinet (in many sizes)
• Applications: all; 25g up to 3 kg. IP 66 option. Small Footprint!
• Versa Rx Slack Belt Conveyor (specially for Pharma)
• Products: all small; sachets, blisters, bottles pharmaceutical products etc.
• Applications: all; 2g up to 300g. 21 CFR Part 11 option.
• Versa Fr 8120 Slack Chain Conveyor
• Applications: all; 25g up to 11kg. Verry good for can / glass lines and in wet.
• Box / Fr 44 Powered Weigh Table Conveyor on separate frame construction
• Products: all; bags, boxes, containers etc.
• Applications: all; 1kg up to 50kg. Fr 44 Also for special “Warehouse” Applications.
• Teorema Slide (static scale) for high speed can lines
• Products: can lines and jars.
• Applications: High speeds 300~700 CPM. 50g to 1,5 kg

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