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If your checkweigher malfunctions, your products might be at risk. In a food manufacturing facility, these machines are essential for ensuring precise and accurate packaging. A slight calibration error can result in financial losses, production delays, and dissatisfied customers.
Regardless of whether you're looking to fix current issues or prevent common checkweigher problems, you've come to the right place. Below, we’ll cover the main issues you might encounter with your checkweigher and how to resolve or avoid these malfunctions.
Common Mechanical Problems and Their Solutions
Checkweighers can suffer from several mechanical issues that affect their performance. Whether you're already dealing with problems or just doing routine maintenance, we suggest checking for the following:
Component Wear and Tear
Different components can degrade over time, causing mechanical malfunctions and system failures. Some components that are particularly prone to early wear and tear include:
- Load cells
- Motors
- Belts
Regular system evaluations and maintenance are key to identifying and addressing worn-out parts before they cause unexpected breakdowns. This proactive approach helps maintain your system's health and extends its lifespan.
Conveyor Belt Issues
The conveyor belt can malfunction in various ways, affecting the overall accuracy and efficiency of the system. Misalignment of the belt can lead to inaccurate weighing results. Frequent inspections and belt calibrations can prevent this problem. Additionally, placing products carefully in the center of the belt can reduce alignment issues.
High-speed conveyor belts can also experience product jams or blockages when large volumes of products move through quickly. Regular cleanings and re-alignments can help prevent blockages. Installing additional sensors or automatic shut-off mechanisms might also help avoid major blockages.
Calibration Problems
Checkweighers must be calibrated regularly to ensure accurate measurements. Initial calibration is crucial as it sets the foundation for future performance. For instance, if you calibrate the unit for 15 pounds, you won't be able to measure three-ounce products accurately, as they may not register properly. It’s important to calibrate the system based on your product weights, setting the zero scale, active zero tracking, and calibration correctly from the start.
Electrical and Software Malfunctions
Many common checkweigher problems stem from electrical issues like shortages and similar failures. Even with regular maintenance, if your system continues to malfunction, you might need to address the following:
Power Supply Interruptions
Assuming your checkweigher uses electricity, power supply interruptions can cause malfunctions. Faulty wiring or power surges due to poor infrastructure can disrupt the machine's operation. Look out for issues like blown fuses, loose data cables, or frequent breaker trips. Addressing these issues might involve upgrading the system’s grounding or power supply to ensure stable operations.
Sensor Failures
The weight sensor needs to accurately detect the product's weight and position on the conveyor belt to determine which items qualify. Poor contact caused by a loose sensor can lead to inaccurate readings, and a completely failed sensor can result in data jumps and incorrect measurements. Regular checks, tests, and secure installations are vital for optimal sensor performance.
Software Glitches and Bugs
Checkweighers rely on software to function. Like any technology, software can glitch or develop bugs, affecting the machine's performance. Keep your software updated to prevent glitches and reach out to your technical team at the first sign of trouble.
Environmental Factors Impacting Performance
Sudden environmental changes, though seemingly unrelated to checkweigher problems, can significantly affect system performance.
Temperature Fluctuations
The load cell requires a stable environment for accurate measurements. Extreme temperature variations can alter the voltage inside the machinery as wire resistance increases, impacting the validity of your results. Most checkweighers come with recommended temperature ranges from the manufacturer. For instance, the IXL Standard Checkweighers from TDI Packsys operate accurately between 32 and 104 degrees Fahrenheit.
Humidity and Moisture Exposure
Fluctuating humidity levels can also impact performance. Excessive moisture exposure can cause the load cell output to differ from what’s displayed. Ideally, humidity should remain between 30% and 85%, though the optimal range depends on your specific machine.
Operational and User Errors
Many of the common problems of checkweighers are not related to the machinery itself but rather user errors. Mistakes made during setup or daily operation can lead to various issues.
Setup and Configuration Errors
Setting up your checkweigher correctly from the start is critical to avoiding future problems. Incorrect configurations or settings can result in numerous malfunctions. Common setup errors include:
- Setting the filter coefficient too low
- Failing to set the zero scale
- Choosing the wrong product model
- Configuring with inefficient power
- Calibrating with the wrong weight
Take care to avoid these mistakes. Opt for a checkweigher that offers installation support from the manufacturer to ensure proper setup.
Deficiencies in Operator Training
Operators need proper training to use and manage the machine effectively. They should know how to select the appropriate load cell for optimal accuracy, operate the software, perform basic maintenance tasks, and troubleshoot malfunctions. If the machine overrides, the team should adjust the products on the belt accordingly to prevent invalid products from passing through production.
All these responsibilities require a thorough understanding of the machinery, software, and product handling. Regular training sessions are essential to minimize human error.
Product Handling Difficulties
Your food products can also contribute to checkweigher malfunctions. If these issues occur frequently, you might need to adjust your packaging or weighing method to prevent further problems.
Uneven Weight Distribution
For accurate readings, the product should be centered on the conveyor belt. Products that are heavier on one side or have uneven weight distribution across multiple sides can cause the checkweigher to malfunction. Heavily lopsided products may yield inaccurate readings. If you notice this trend, consider adjusting your sensors, recalibrating, or switching to a different checkweigher.
Products Prone to Sticking or Blockages
Certain products tend to cause blockages more often. If you encounter issues with sticking and backups, you may need to modify your packaging to reduce downtime and prevent future mechanical problems.
Preventative Maintenance and Ongoing Solutions for Smooth Operations
With all the common checkweigher problems covered, let’s talk about how to prevent future malfunctions. Keeping your system running smoothly requires regular upkeep and proper training. Here are some recommendations:
Routine Maintenance and Inspections
Regular maintenance ensures your system stays healthy and operational for as long as possible. Some basic tasks to perform during routine maintenance include:
- Thorough cleaning of the system
- Lubrication of all moving parts
- Checking components for loose screws or fasteners
- Inspecting the load cell
- Checking timing belts
- Inspecting all wiring for loose connections
- Resetting chips
- Testing electrical grounding
- Measuring humidity and temperature points
- Calibrating the machine using test weights
Address any significant concerns immediately.
Proper Operator Training
Your operators should receive comprehensive training from the start and ongoing education after software updates. Regular check-ins are also necessary to ensure everyone performs their duties correctly. Key topics to cover in training include:
- Selecting the correct load cell
- Operating the software
- Performing maintenance
- Troubleshooting common problems
- Adjusting the conveyor belt
- Responding to overrides
Upgrading or Modernizing Equipment
If your checkweigher still malfunctions despite regular maintenance and operator training, it might be time to upgrade to a more suitable, modern machine. Newer models offer enhanced accuracy and stability, reducing errors and malfunctions. At TDI Packsys, all our checkweighers come with easy assembly and cleaning instructions and highly sensitive load cells that don’t require daily calibration.
Choose TDI Packsys for Seamless Operations
Avoid the common problems of checkweighers by upgrading your system today. Call TDI Packsys at (877) 834-6750 to learn more about our advanced inspection machinery.