Weighty issue: redesigning manufacturing machinery to meet new needs

To cater to changing needs in terms of sustainability and time and cost savings, weighting instrument manufacturer company Mettler Toledo has redesigned its new C2 Redesign Highload Checkweigher to perform real-time completeness checks on each product pack.

We spoke to Dirk Bettels, Senior Project Manager at Mettler Toledo who said this was a strategic response to the dynamic needs of cosmetics manufacturers.

“By integrating enhanced efficiency, a sustainability focus and a customer-centric approach, Mettler-Toledo aims to empower the cosmetics industry with a reliable and innovative checkweighing solution​,” he said.

“This solution not only addresses the immediate challenges of production but also aligns with the long-term goals of reliability, adaptability and compliance within the cosmetic manufacturing landscape.”​

According to Bettels, the redesign will offer cosmetics companies:

Improved production and flexibility​
The incorporation of larger conveyor sizes, capable of supporting belt widths up to 600mm, will accommodate diverse product handling needs. This flexibility allows seamless integration into different cosmetic production lines and contributes to operational efficiency.

Lower costs​
The C2 Checkweighing portfolio introduces features such as a 50% reduction in motor power consumption and a 50% reduction in different wear parts. This in turn will simplify maintenance, improve inventory management and lower the total cost of ownership.

A R&D and customer-centric approach​
The decision to redesign was informed by extensive research and development, with a focus on listening to customer feedback and addressing specific needs. Mettler-Toledo has aimed to provide a checkweighing solution that is future proof, evolving with industry demands.

Energy savings and reduced environmental impact​
In addition to production improvements, the redesign better fits sustainability demands, emphasising energy savings and reduced environmental impact. By optimising energy consumption and reducing operational expenses, cosmetics companies can align their manufacturing processes with sustainable practices, contributing to environmental responsibility.

Real-time completeness checks on product packs​

The company's systems benefitting from this redesign are the C23 PlusLine and C21 StandardLine Checkweigher.

The new machine will perform real-time completeness checks on each product pack, so it meets the specified weight as pre-programmed into the system.

“For instance, in the case of a bottle of shampoo, the technology detects any deviation from the required weight, indicating potential issues such as missing bottles,”​ explained Bettels. “This product inspection solution plays a crucial role in helping to prevent product recalls, mitigating associated costs and safeguarding brand reputation.​ Importantly, this functionality aligns with stringent industry regulations and standards, reinforcing compliance for cosmetic brands.”​

The machine can weigh products of various weights, shapes and sizes, which makes it useful for cosmetics companies that produce a wide range of products.

According to Bettels, the system easily integrates with various systems, including customers' enterprise resource planning. This integration offers efficient data flow and communication throughout the manufacturing process. "Connectivity through interfaces like Ethernet and OPC UA Protocol enhances compliance, brand protection and facilitates comprehensive data analysis," ​he said. "This emphasis on reporting not only leads to the accuracy of checkweighing but also contributes to data-driven decision-making."​