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If your checkweigher malfunctions, your products could suffer. In a food manufacturing facility, checkweighers play a crucial role in ensuring precise, accurate, and efficient product packaging. Even a minor miscalibration can result in lost profits, downtime, and dissatisfied customers.
Whether you're looking to troubleshoot your machinery or prevent common checkweigher issues, you've come to the right place. Below, we’ll cover the primary problems you might encounter with your checkweigher and how you can solve or avoid these malfunctions.
Common Mechanical Issues and Their Solutions
Checkweighers can experience a variety of mechanical problems that affect their performance. Regardless of whether you're dealing with existing issues or just doing routine maintenance, we suggest checking for the following concerns:
Component Wear and Tear
Over time, various components can degrade, leading to mechanical malfunctions and system failures. Components that are particularly susceptible to premature wear and tear include:
- Load cells
- Motors
- Belts
Routine system evaluations and maintenance are essential to check these components for signs of wear early on. Fixing or replacing worn-out parts before they break down can keep your system running smoothly and extend its lifespan.
Conveyor Belt Problems
The conveyor belt can malfunction in several ways, affecting the system's accuracy and overall performance. Misalignment of the belt can result in incorrect weighing results. Regular inspections and calibrations of the belt 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 and blockages when large numbers of products move through the system rapidly. Preventing these blockages can be achieved by regular cleanings and re-alignments to ensure the belt operates optimally. Installing additional sensors or automatic shut-offs might also help prevent major blockages.
Calibration Issues
Checkweighers need frequent calibration to avoid inaccurate measurements. It's also critical to calibrate the machine correctly from the outset. The initial calibration sets the tone for the checkweigher’s performance moving forward, determining the general weight category.
For instance, if you calibrate the unit with 15 pounds, you won't be able to accurately weigh three-ounce products, as they might zero out. Based on your product weights, you must set the zero scale, active zero tracking, and calibration correctly from the beginning.
Troubleshooting Electrical and Software Malfunctions
Some of the most common problems with checkweighers stem from electrical shortages and related failures. If you’ve kept up with your maintenance but the system still fails, you may need to address the following:
Power Supply Interruptions
Assuming your checkweigher runs on electricity, power supply interruptions can cause malfunctions. Issues within your electrical system, such as faulty wiring or power surges due to poor infrastructure, can disrupt the checkweigher’s operation. We recommend checking for issues like blown chassis fuses, loose data cables, or frequent breaker trips.
If you’re experiencing power supply interruptions, you may need to improve the system’s grounding or power supply to ensure stability. This can help prevent outages.
Sensor Failures
The weight sensor should accurately detect the product weight and location on the conveyor belt to identify which products meet the criteria. Sensor inaccuracies happen if the sensor becomes loose, causing poor contact. The sensor might also fail entirely, leading to data inconsistencies and inaccurate measurements.
In every case, the sensor must be inspected, tested, and secured regularly for optimal functioning.
Software Glitches and Bugs
Checkweighers rely on software-fed data to operate. Like any technology, your software can glitch or develop bugs, affecting the checkweigher’s performance. Ensure all necessary software updates are performed to prevent glitches and contact your technical team at the first sign of failure.
Environmental Factors Affecting Checkweigher Performance
Sudden environmental changes might not seem like typical checkweigher problems, but extreme environmental fluctuations can significantly impact system performance.
Temperature Variations
The load cell needs minimal environmental interference for accurate measurements. Extreme temperature fluctuations can affect the voltage inside the machinery as wire resistance increases, impacting the validity of your results.
Your checkweigher should come with temperature recommendations from the manufacturer. For example, the IXL Standard Checkweighers from TDI Packsys offer accurate performance in temperatures ranging from 32 to 104 degrees Fahrenheit.
Humidity and Moisture Exposure
Fluctuations in humidity can also impact performance. Excessive moisture exposure can cause the load cell output to vary from what is displayed. Humidity should generally remain between 30% and 85%, but the ideal range depends on your specific machine.
Avoiding Operational and User Errors
One of the most common checkweigher problems isn’t related to the machinery itself. User error can lead to various issues from initial setup to daily operation.
Common Setup and Configuration Errors
Setting up your checkweigher correctly from the start is essential to avoid errors later on. Configuring the wrong product type or failing to adjust a few settings can lead to numerous malfunctions. Some common configuration errors during setup include:
- Setting the filter coefficient too small
- Failing to set the zero scale
- Selecting the incorrect product model
- Configuring with inefficient power
- Calibrating with the wrong weight
Take extra care to avoid these mistakes. Choosing a checkweigher that comes with installation support from the manufacturer can ensure your system works properly.
Deficiencies in Operator Training
Operators must be trained to use and manage the machine effectively. They should know how to choose the appropriate load cell for optimal accuracy, operate the software, perform basic maintenance tasks, troubleshoot malfunctions, and more. If the machine overrides, the team must adjust the products on the belt accordingly without letting invalid products pass through production.
All of these duties require detailed knowledge of the machinery, software, and product. Operators should receive regular training to prevent human error.
Difficulties With Product Handling
Your food products can also cause the checkweigher to malfunction. If you face these difficulties often, you may need to adjust your packaging or weighing mechanism to prevent further issues.
Products With Uneven Weight Distribution
The product should be centered on the conveyor belt for accurate readings. Products that weigh significantly more on one side or spread unevenly across multiple sides can cause the checkweigher to malfunction.
Heavily lopsided products may not provide the most accurate readings. If you notice a pattern, you may need to adjust your sensors, recalibrate, or consider a different checkweigher.
Products Prone to Sticking or Blockages
Certain products tend to cause blockages more frequently than others. If you notice issues with sticking and back-ups, you may need to adjust your packaging to prevent downtime and future mechanical concerns.
Preventative Maintenance and Ongoing Solutions for Smooth Checkweigher Performance Moving Forward
Now that we’ve covered the most common checkweigher problems, let’s discuss how you can avoid future malfunctions. Maintaining your system in excellent condition requires regular upkeep and proper training. We recommend the following:
Conduct Regular Maintenance and Inspections
Routine maintenance keeps your system healthy for as long as possible, preventing inaccurate readings and other malfunctions. Here are some basic tasks to perform during your standard maintenance:
- Clean the system thoroughly
- Lubricate all moving parts
- Check all components for loose screws or fasteners
- Inspect the load cell
- Inspect timing belts
- Inspect all wiring for loose connections
- Reset chips
- Test electrical grounding
- Measure humidity and temperature points
- Calibrate the machine using test weights
If you notice any significant concerns, address them immediately.
Ensure Proper Operator Training
Operators should be trained correctly from the start and ongoing for optimal system performance. Besides the initial onboarding, follow up with continuous training after any software updates. Regularly check in with the team to ensure everyone performs their roles correctly.
Include these basic points in training:
- Selecting the correct load cell
- Operating the software
- Performing maintenance
- Troubleshooting common problems
- Making conveyor belt adjustments
- Responding to an override
Upgrade or Modernize Your Equipment
If your checkweigher frequently malfunctions despite routine upkeep and team training, it may be time to upgrade to more suitable, modern equipment. The latest models offer maximum accuracy with high-speed stability, reducing errors, malfunctions, or headaches. 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 Hiccup-Free Operation
Avoid the common problems of checkweighers by upgrading your system today. Call TDI Packsys today at (877) 834-6750 to learn more about our advanced inspection machinery.