Dairy &

Cheese
Industrial Weighing and Measuring

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.
Networked Statistical Quality
Control
At six different test places, line operators control quality parameters such as
color, taste, weight or expiry date of the

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:
Production (period) mean value
Number of violations of the legally
defined tolerance limits
Mean standard deviation of the production (period)

News

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

METTLERTOLEDO

Dairy & Cheese News 3

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

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.

METTLERTOLEDO

Dairy & Cheese News 3

Statistical Quality Control

Quality parameters
of finished products
Every 1520 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

Package quality parameters

Ice cream weight

Chocolate coating weight
Volume (Density)
Taste
Color

Net weight
Barcode
Expiry date
Label
Box aspect
Plastic wrap
Typical FreeWeigh.Net monitoring screen
showing ice cream weight, chocolate weight
and volume (density)

Customizable test reports

Mr. Gerardo Bermejo Barrera concludes:

During our long-lasting relationship with
METTLERTOLEDO, we have always implemented innovative solutions from a competent system specialist. FreeWeigh.Net

METTLERTOLEDO

Dairy & Cheese News 3

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.

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.
Foil and film lids
Parmalat has installed eight Safeline detection systems which are a combination of
stand-alone Signature machines and doublehead systems which combine the Signature
with a ferrous-in-foil detector head.

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
their quality reputation, the standard of
their technology and because they were
competitive.

METTLERTOLEDO

Dairy & Cheese News 3

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

METTLERTOLEDO

Dairy & Cheese News 3

IND560
process
terminal

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, RS485/422, 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, 5000d 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
METTLERTOLEDO

Dairy & Cheese News 3

A Wide Range of Solutions

to Improve Processes

1. PUA579 Drive-through floor scale

2. BBA449 over/under check scale with colored backlight
3. GarvensS3SHARK Combiweigher
4. In-line turbidity, pH and conductivity sensors

EHEDG

colorWeight

2
4

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

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

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.

GARVENS

SAFELINE

SAFELINE

Checkweighing

Metal Detection

X-ray Inspection

Unrivalled connectivity options...

Visit for more information

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.

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 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.

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.

Subject to technical changes

Mettler-Toledo PI
Printed in UK
MTPI-UKPO-PICBE-0506-1M

Checkweighing
Metal Detection
X-ray Inspection
Service XXL

Breadth of experience, depth of capability

for complete product inspection solutions

www.mt.com/pi

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

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.

Metal Detection & X-ray Inspection

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.

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

SAFELINE

Product Inspection Solutions

Product Inspection

System Integration

Checkweighing

Fully Integrated Solutions

tailored to suit your needs

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

www.mt.com/dairy-cheese
For more information