Weighing the Benefits of Scale Equipment

Ingredients dispensed into the container cause the suspended end of the weight sensor to deflect slightly as it absorbs the force of the load. The force measurement is then translated as the ingredient’s weight. As subsequent ingredients are added, the weight sensor deflects an appreciable amount from its current position to represent the new ingredient’s weight. The suspended end of the load cell then returns to its initial position once the container is emptied. Adding to this design, some weight sensors have two pairs of electronic sensors  located on the outside of the weight sensor structure, one pair on top and one on the bottom. This sensor arrangement helps ensure uniform compressive strain throughout the structure, which eliminates the effects of end loading, side loading and torsion effect.

Indicators are the heart of this weighing system, collecting and communicating data throughout the manufacturing enterprise for heightened process transparency and streamlined, cost-effective production. Indicators are also multitaskers, with some capable of simultaneously monitoring several independent scales, as well as directly controlling automated weight-based operations. 

To facilitate at-a-glance decipherability, indicators can provide a combination of text and graphics that clearly convey process status and product weights. For instance, horizontal bar graphs can display over/under readings in checkweighing operations, vertical bar graphs display ingredient amounts, and pie graphs track rapid fill operations. This reduces read errors and allows operators to quickly take action if a process becomes obstructed or products do not meet weight regulations.

With fast-paced production speeds and minute margins for error, indicators with sophisticated data acquisition and management improve efficiency and throughput. For example, indicators can be programmed to automatically recall recipes, track product usage and update inventory records based on the amount of product used or remaining. Plus, indicators that interface with common industry-standard protocols enable the device to connect with diverse serial devices, including printers, bar code scanners, label printers and remote displays. This allows data to be stored and printed from the indicator, downloaded and reformatted by a host PC or accessed via an Intranet or Internet connection.

Given that pharmaceutical end products must be pure and consistent, batching and blending applications must be verifiably exact to protect product integrity. In many plants, manufacturers store raw ingredients or pre-mixed formulas in tanks or hoppers to be dispersed during production. By integrating weight sensors and indicators with these containers, users can not only ensure accurate measurements and product consistency, but can also perform advanced data acquisition and inventory management procedures. 

Coupling weight sensor technology with an indicator that stores recipe components ensures the exact amount of each ingredient is dispensed, without requiring operator intervention. The weight sensors are placed on each leg of the material container to capture readings, and an indicator with recipe-recall is integrated with plant devices and communicates with PLCs, PCs and other vital operating systems to provide an automated weighing solution. Once the measurement parameters have been entered into the indicator the automated weighing systems can be configured to recall recipes, routinely measuring according to the specified weight values or percentages.

As the pharmaceutical product moves through the production process, the indicator monitors the weight sensor to identify when the proper amount of product has been released. Once the product meets a configured dispensing station, the indicator sends a signal to begin dispersal of the first ingredient until the set point is reached. The indicator then uses its output to communicate this status to the filling equipment’s control system which, in turn, closes the product release valve on the first hopper and begins dispensing the second ingredient. The process continues until the batch is complete. Additionally, some indicators can store multiple recipes at once to ease product changeover.

Further, these automated scale systems can accommodate rapid product switchover, controlling multiple weighing requirements in a single application while delivering high-quality results. For additional automation, indicators can be configured to track product usage, keeping a running total for inventory purposes — maximizing process efficiency and reducing inaccuracies associated with operator error. 

Using a system that automatically tracks material disbursement and usage enables operators to increase inventory control, product quality and customer satisfaction, all while decreasing labor and production costs. Automated electronic scale systems offer unmatched reliability with minimal human error and costs. 

Since customers depend on pharmaceutical products to improve or maintain their health, any minute inconsistency could have drastic consequences. Blending and batching applications hinge on a manufacturer’s ability to obtain accurate measurements. Therefore, utilizing an automated weighing system that makes operator monitoring obsolete, manufacturers can perform frequent quality checks, while eliminating the need for a separate checkweigher and manual supervision. By utilizing the indicator’s ability to communicate with and control plant devices, these applications will be completed the same way every time, which promotes product consistency. 

Inventory management is directly correlated with a company’s pocketbook, as both shortages and waste result in significant lost revenue. For instance, when pharmaceutical plants experience shortages, this can lead to production halts, and extended downtime can be costly. Alternatively, given that some of the materials used to make these products have a window of viability, any excess, unusable materials must be thrown away, translating into lost profitability. 

Automated scale equipment actively tracks and monitors product usage and remaining amounts, logging and communicating real-time product inventory updates. Plus, to ensure these records are constantly refreshed, the system relays this information to office computers, signaling when product inventory is low and reordering is necessary. For example, indicators can be programmed to measure the weight of a tank after each time the product is dispensed, repeatedly calculating the amount left. The indicator automatically totals product usage and eliminates risks of shortage and surplus concerns. 

Today’s focus on efficiency and cost-effectiveness will continue to drive the way manufacturers piece together the components that make up their plant floors. Though the configuration may evolve, using equipment that promotes productivity and quality while simultaneously driving down costs will remain a constant. Implementing scale equipment integrated fully into production is a key element in streamlining pharmaceutical operations for enhanced profitability and customer satisfaction.