Product Application Guidelines

Checkweighers
Checkweighers Application Guide Siemens Level and Weighing

Table of Contents
Preface ......................................................................................................................................... 3
Introduction ................................................................................................................................. 4
Checkweigher Selection ............................................................................................................. 5
Application and Mounting Guidelines ...................................................................................... 5
Scale Considerations ................................................................................................................. 6
Load Cells ................................................................................................................................. 6
Mobility ...................................................................................................................................... 7
Cleaning .................................................................................................................................... 7
Scale verification ....................................................................................................................... 7
Statistical Analysis ..................................................................................................................... 8
Standard Distribution ................................................................................................................. 8
Applications ............................................................................................................................... 8
Filling Applications ................................................................................................................... 11
Counting Applications .............................................................................................................. 11
Application Considerations ..................................................................................................... 11
Rejecting Items ........................................................................................................................ 11
Calibration ............................................................................................................................... 13
Installation ............................................................................................................................... 13
Inclines .................................................................................................................................... 13
Temperature ............................................................................................................................ 13
Adhesion ................................................................................................................................. 13
Causticity ................................................................................................................................. 14
Maintenance and Modifications ............................................................................................... 14
Maintenance ............................................................................................................................ 14
Modifications ........................................................................................................................... 14
Material Build-up ..................................................................................................................... 15
Material Spills .......................................................................................................................... 15
Product Selection ..................................................................................................................... 15
Checkweigher.......................................................................................................................... 15

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Checkweighers Application Guide Siemens Level and Weighing

Preface
The contents of this guide are intended to be used for pre-sales activities when a checkweigher solution is
under consideration. The information required to properly size a checkweigher does not take into consideration
many of the factors that are part of the environment or the system which can lead to adverse performance if not
properly managed or eliminated.

Please refer to the appropriate checkweigher operating instructions for full specifications as well as installation
and calibration procedures. Siemens does not offer checkweighers, but can supply load cells and mounting
units. For more information visit our website at www.siemens.com/weighing.

When installed and applied according to the guidelines, checkweigher design and manufacture results in
greater accuracy. To help the user maintain the accuracy and performance of the checkweigher, this guideline
provides recommendations for the proper application of checkweighers under specific material handling and
environmental conditions.

The application of a checkweigher is tailored to the individual requirements of each process. Detailed
information about the material, process, control, and size of the unit are all considered when engineering a
checkweigher.

Compared to a static weighing application, a checkweigher is an independent machine that interfaces between
two connection points to weigh discrete items in motion. Every component of a checkweigher is configured to
the specific needs of the application. The material characteristics and the way material travels on the belt is a
large factor in the sizing of a checkweigher. To prevent instability, discharge speeds need to be slow enough to
ensure that each item enters the checkweigher at the same velocity. Motors are sized to exceed the power
demands of starting under full loading conditions. Gearboxes are selected to achieve a specific belt speed that
will maintain a smooth transfer from input to output on the conveyor. The scale components are configured so
that load cell capacity is sufficient in order to meet the requirements of accuracy. This is all in addition to normal
conveyor design that ensures the frame and structure is rigid enough to handle the load and dynamic forces of
conveying the product. Throughout the configuration process, strict safety standards and components are
applied including, proximity switches, metal detectors, x-ray machines or light curtains. Applying these rigorous
design standards ensures that checkweighers are designed specifically for weighing accuracy and feeding
consistency.

The guide is meant to be read chronologically, to illustrate how aspects of the application can combine to
create poor performance from the checkweigher.

Note: Other checkweigher solutions are available such as non-automatic weighing on a platform scale
or balance. These technologies do not have the same point of reference as an in-motion checkweigher
which is the basis for this application guideline.

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Checkweighers Application Guide Siemens Level and Weighing

Introduction
Checkweighers can:

• Verify product weight of discrete items such as raw foods, pre-packed products, filled cartons etc.
• Avoid product quality issues or potential recalls
• Provide a 100% overview of production output data
• Provide legal for trade accuracy

A checkweigher is a weighing solution that combines two components:

Checkweigher (with weigh scale)

Checkweighers weigh the product being conveyed and ensure it is within the set tolerances required. The
product is removed from the production flow if it is outside of the tolerances. Checkweighers are generally
based on a belt conveyor, but can also be integrated into roller style conveyors or other continuous flow
productions. A checkweigher classifies and segregates items by weight.

Terminal

Checkweighers are generally not well suited to a continuous flow of material and should be used for individual
products or discrete items.

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Checkweighers Application Guide Siemens Level and Weighing

Checkweigher Selection
Choose a checkweigher that best suits your application, based on the following criteria:

• Maximum product weight

• Conveyor speed
• Product size
• Maximum material temperature
• See page 13 for more information on specifying your checkweigher using temperature.

Use your application criteria to find an appropriate checkweigher.

Application and Mounting Guidelines

Checkweighers are typically used in four main areas:

1. Pre-packaging: product weight is verified before being packed to ensure quality and regulatory standards
are met.
2. Primary packaging: product in package weight is verified before bulk packaging to prevent non-conforming
processing into the next phase.
3. Secondary packaging: multiple products are consolidated and weight is verified prior to case packaging.
4. Case and bulk: packaged items are packed in a larger container and weight is verified to ensure optimum
packing and shipping data is correct.
Throughput and the speed of the conveyor can be inversely proportional to accuracy. In order to achieve the
highest accuracy, the product must be on the scale long enough for the load cell to react to the change in
weight and stabilize. It is not uncommon for multiple production lines to be used at a reduced conveyor speed,
for higher accuracy, while achieving the same overall throughput. Checkweigher length can also be optimized
based on product size and conveyor speed.

In static testing with test weights, the checkweigher’s performance is repeatable, linear, and reacts minimally to
ambient temperature changes. The checkweigher is a very accurate machine in static mode. The checkweigher
application will determine how well the checkweigher performs in dynamic mode with material conveying.

Legal standards require that the product weight of a packaged item cannot not be significantly less or more
than the stated weight on the package and that a group of packages should be equal to or greater than the
labeled weight.

The following guidelines will reduce the need for further modification after installation of your checkweigher:

• Condition the product flow as required to provide repeatable flow patterns for consistent movement
from the infeed conveyor to the checkweigher.
• Ensure that the outfeed conveyor, downstream from the checkweigher, will not cause material back up
at the discharge.
• Avoid products that cannot be stabilized on the conveyor and/or materials that will stick to surfaces of
the checkweigher.
• Protect components of the checkweigher system from damaging, caustic material. Damage can come
from the weighed material, as well as backup air from the downstream process or air flow from the
upstream process.
• If required, ensure that the checkweigher has the necessary equipment required for operation within a
hazardous environment.

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Checkweighers Application Guide Siemens Level and Weighing

• Ensure that the temperature of the material being weighed falls within the checkweigher temperature
range. The material temperature can have a greater range than the ambient conditions around the
checkweigher. Also ensure that the ambient air temperature is not unreasonably high.
• Isolate or remove any influence from vibration.
• Reference a known material sample during verification and final calibration of the checkweigher to
ensure the system is providing necessary accuracy.
Below are two methods for referencing a known sample:
o Pre-weigh and then run a sample through the checkweigher.
o Collect and weigh a sample after it has been run through the checkweigher.

Scale Considerations
Load Cells
Load cell requirements will change depending on the type of scale in the checkweigher.

Small scales are generally no larger than 24 x 24 inch (600 x 600 mm). For this reason, a single point load cell
can be mounted to the center of the scale. Single point load cells can handle capacities up to 1800 lb (800 kg).
The load cell should be mounted so that the center of the cell is aligned with the center of the scale.

For scales that require a higher accuracy or larger weighing area, 4 load cells are required to support the scale.
Bending beam or ring torsion style load cells should be used for these configurations.

0.3 to 500 kg
Single point (0.7 to 1100 lb)

10 to 350 kg
Bending beam (22 to 770 lb)

0.06 to 60 t
Ring torsion (0.06 to 60 Lt)

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Recommendation
Ensure that any scale has the right load cell for the capacity and environmental conditions. Multiple load
cell scales should use self-aligning mounts to ensure that no mechanical binding occurs during
deflection under load.

Mobility
Checkweighers can be mobile or even part of a moving conveyor to weigh goods more conveniently. Mobile
checkweighers, of any kind, must be zeroed before they can weigh goods. This will ensure that influence of an
uneven floor does not affect weighing accuracy.

Recommendation
Do not weigh goods while moving the checkweigher. Ensure that obstructions close to the scale do not
contact the goods or checkweigher scale, as this can affect accuracy. During checkweigher transport,
use fork lift guides to ensure the forks do not damage the load cells.

Cleaning
In applications where the checkweigher will be cleaned frequently, a stainless steel construction is more suitable as it
allows for easy access below the platform. Drain holes or non-slip finishes are also available for flush mount units in
wet environments.

Recommendation
Ensure that scale and load cell construction is stainless steel. At a minimum, load cells should be IP67
rated.

Scale verification
A product test is the best way to verify the performance of a checkweigher. To perform a product test, weigh a
product on a trusted scale with a resolution of at least 5 times that of the checkweigher. Run the product over
the checkweigher 30 to 100 times to establish a normal distribution. This will provide a mean as well as
deviations to the mean and is the basis for checkweigher performance. Linearity is also very important when
using a checkweigher. Linearity is best tested using certified weights in a static state. You can apply calibration
weights while the conveyor is running as a quick and easy way to calibrate the system and ensure it has not
drifted into an uncalibrated state.

Recommendation
Calibration weights should be used to meet the needs of day to day production verification. To verify
accuracy for critical applications, run a sample product over the checkweigher to establish a set of data
as required. Consider the accuracy of the scale when creating a calibration schedule.

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Checkweighers Application Guide Siemens Level and Weighing

Statistical Analysis
Standard Distribution
Throughout the production cycle, products or materials go through many steps and movements. Changes in
the environment, deviations in the manufacturing recipe, machine tolerances, as well as the movement of the
product itself can lead to small changes in weight results. As long as these random events do not become
significant, the production results will follow the laws of standard distribution or normal distribution.

In order to properly understand standard distribution the following definitions should be understood:

Mean Is the average of the sum of all the measured values divided by the number of values. To
avoid underweight products, the target weight is typically set slightly higher than the mean
value.
Deviation Is the spread of the values measured from the lowest to the highest weight. The deviation
value is a calculation based on all the weights measured to determine the range of the
deviation. It may be a large value or a very small one, but statistically the standard
distribution rule will apply no matter what the deviation range.

In a standard distribution analysis, 68% of products are within ± 1 deviation (spread value, represented above
by the σ symbol) from the mean (average value, represented above by the µ symbol), 95% of products are
within ± 2 deviations from the mean, and 99.7% of the products lie within ± 3 deviations from the mean. This is
also referred to as the “68-95-99.7” rule. According to this rule, all production will be within 3 deviations of the
mean.

The primary purpose of a checkweigher is to determine the mean and deviation values so that the production
process can be optimized, not only meet legal requirements, but also to control the process, and increase
profitability.

Applications
The ideal product for a checkweigher is one that is tightly packaged and does not jostle, shake or vibrate when
being conveyed.

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Sloshing in bottled liquids can create scale errors if the load cell(s) cannot reach a stable measurement due to
product movement. If possible, ensure that the product has a low center of gravity while being weighed.

Also make sure that the product container is closed. Unwanted dead loads on the scale, left behind by leaking
or spilled product, can result in performance issues.

Always confirm that the orientation of a product is repeatable.

The checkweigher must only have one item on the scale at any time. The spacing of items needs to be
adequate enough to ensure that partial support of a new product or previously weighed product does not
impact measurement of the current product.

The change in conveyor speed should not exceed 15 m/min (49 fpm) as this could potentially upset the product
or change its orientation.

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Checkweighers Application Guide Siemens Level and Weighing

A general rule for spacing is as follows:

Conveyor speed = Packages per minute x Pitch

Where: Pitch is the distance between the products from leading edge to leading edge

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Checkweighers Application Guide Siemens Level and Weighing

Filling Applications
In filling applications, the container is filled to a certain set-point while the conveyor is stopped or moving. The
container is on the scale and the material is added to it. The aim of a filling application is to be as accurate as
possible. Accuracy establishes a production process that is optimized for maximum profit. It is also important
for the environment as some material may be hazardous and a spill could be dangerous. Less variance in
filling ensures that the target weight of a product is closer to its labelled weight. Remember, the tare weight of
the container must be removed from the measurement to ensure that only product weight is monitored.

Counting Applications
Checking for missing items in a package and measuring the weight of a complete item are examples of
counting style applications. It is important to note that in counting applications where packages are checked for
missing items, the weight of an individual item must be no less than 3x the total standard deviation. If the
component weight is less than this value, a pre-weighed solution must be used.

Application Considerations
Rejecting Items
When a checkweigher measures a product that is not within the tolerance specified, it needs to be identified
and removed from the production flow. The product characteristics are the best means to determine which
type of rejection method to use.

An air jet rejecter can be used on products with a weight that does not exceed 500 grams (1.1 lb). The air jet
blows the product off the conveyor and into a reject bin. The air supply to the rejecter must he constant and
present to ensure proper isolation of the deviant product.

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Push-off rejecters are the most widely used rejecters. They can accommodate a wide range of product shapes
and sizes. Typically pneumatically driven, these rejecters use a piston to push the product off of the conveyor.

Plow rejecters can provide a more gentle removal than air or push off rejecters. They are also ideal for
products with open tops where the product can be re-claimed and put back into the production stream. Sweep
off rejecters operate in the same manner.

Gates can divert the product down another conveyor path for reclamation or rejection. Also, normally
pneumatically driven, they can be programmed to provide a soft impact to protect the product from damage.

Lift gates or drop down gates mechanically rotate up or down to remove the rejected product from the production
flow. They are ideal for products that are difficult to move away from the conveyor flow.

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Checkweighers can provide an alarm or stop the conveyor if too many items have been rejected in a row to
indicate a production issue.

Calibration
Checkweighers, like any other continuous weighing device, can be calibrated using either calibration weights or
theoretical electronic calibration. The most popular option is calibration weights. The weights attach to the
scale section of the checkweigher and provide a reference point to create a calibration curve. Additional
weights can be applied to check the linearity of the unit.

Installation
The connection points of a checkweigher are the infeed conveyor and outfeed conveyor. It is important to note
that the checkweigher must not come into contact with either of these points and be fully independent. The
checkweigher must be installed on a sturdy platform or support structure to ensure that twisting or bending
does not occur during or after installation.

The checkweigher requires a clearance on the belt or chain change side of the device for cleaning and
replacement of the conveyor. Access is also required on the opposite side for calibration and cleaning.

Inclines
Checkweighers are generally installed horizontally. An inclined unit can accurately weigh products, however
the maximum angle is 10°. Variable inclines are not recommended due to fluctuations in material movement
during conveying.

Temperature
The material on a checkweigher is isolated from any electronic component which allows for a higher material
temperature than ambient conditions. Without special features, a typical checkweigher can convey materials
up to 100°C (212°F) however, higher temperatures are possible up to 200°C (400°F).

Note: The ambient air temperature surrounding the checkweigher should not exceed 55°C (131°F) in
any application.

Adhesion
It is vital that sticky materials do not build up on the checkweigher. Adhesive materials that build up on the belt
are a concern when the buildup hampers movement of the product. Buildup can also shift the zero reference. If
the material sticks, it can create an inaccuracy if it is continuously weighed without discharge.

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Material buildup will cause a calibration shift due to the continuous weighing of the material, or due to the
additional build up of material over the dynamic scale parts. Most materials will be self-cleaning on the belt
surfaces due to the continuous motion of the conveyor. Some materials will not be self-cleaning and will require
anti-stick coatings. There are also some materials that will simply not be suitable for weighing with a
checkweigher, especially if the moisture content is too high.

Causticity
Materials that have caustic or corrosive qualities can damage checkweigher components. Sometimes the
material being measured is not caustic itself, but caustic vapors may be present from the processes
downstream or upstream from the checkweigher.

Checkweigher load cells, the most critical components, are fabricated from stainless steel which is resistant to
damage from caustic materials. Other steel components can also be made of stainless steel when the device is
to be used with a caustic substance.

The load cell’s encapsulated strain gauges are protected by a gel compound. Some caustic materials can
damage the load cell potting gel and eventually the strain gauges, especially where the material has high
moisture content. When there is concern about the suitability of a caustic material, use a hermetically sealed
IP68+ load cell.

In applications for caustic material, the feeding parts of the checkweigher may require special consideration to
prevent chemical reaction between the weighed product and the belt. Epoxy paint and synergistic coatings may
be required as protection of the gear reducer and motor.

The standard, type 304 stainless steel, is suitable for most caustic material, but some will require type 316,
which has a slightly better chemical resistance.

Maintenance and Modifications

Maintenance
Once the checkweigher is installed with the conveyor, it is part of a weighing system and will now require more
care. To ensure accurate weighing, the checkweigher and surrounding area must be properly maintained.
Perform the following maintenance for optimal checkweigher operation:

• Consistently spaced product flow

• Lubrication of all bearings
• Proper conveyor speed
• Proper cleaning and scraping
• Proper material and spillage control

Maintenance Precautions:
• When welding near the scale, do not allow current to pass through the checkweigher scale.
• Reset the shipping stops to reduce physical shock to the load cells during maintenance.

Modifications
Any changes to the process and/or related equipment could have a profound effect upon operation and the
resulting accuracy of the checkweigher.

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Recommendation
Consult your Siemens representative for advice regarding checkweigher installation in a modified
process system.

Material Build-up
Keep the conveyor belt and associated equipment as clean as possible, so that the scale measures only the
loads intended and not the added load due to buildup on the feeder. To remove materials that stick to the
equipment, use good quality cleaning tools such as scrapers, brushes, and plows. Although scales can be
frequently and automatically recalibrated at no load (zero), it is not a good practice to allow material buildup to
remain on the conveyor.

Material Spills
General good housekeeping is always important. Spilled material can adversely affect checkweigher operation, and
result in lost production, when it wedges between dynamic parts preventing proper scale deflection.

Recommendation
Do not overload the checkweigher. As a precaution, install by-pass systems to keep spills from reaching
the checkweigher.

Product Selection
Checkweighers
There are many styles of checkweighers available: low capacity, chain style, belt style, and high capacity.
Generally there are three factors to consider when you select a checkweigher:

Application needs drive the specific selection of models and options. The environment will also play a part;
the checkweigher should be stainless steel in corrosive areas or near sea ports. If the location is considered
hazardous, approved electrical components will be needed.

Price point Influences the selection of the type of checkweigher. Belt style models are less expensive, but if
the application is not suited to them, they should not be used.

Checkweigher sizing Limitations based on application needs and product features or performance will narrow
the selection of the product in most cases. Product size, sensor optimization, and material flow are all
considered when a checkweigher is engineered.

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Siemens Level and Weighing
1954 Technology Drive
P.O. Box 4225 For more information
Peterborough, ON
Canada K9J 7B1
email: [email protected] www.siemens.com/weighing