A Comprehensive Guide to Multi Head Weighers

Multi-head weighers or scales are game-changers in aotomatic filling equipment field. This advanced technology is essential for fast, precise packing businesses.

Multi-head weigher machines are essential to contemporary packing, weighing and filling a variety of items with precision and efficiency.

Technical purchasing, production engineers, and business owners use the multi-head weigher to boost efficiency and ensure product quality.

Join us as we discuss how multi-head scales affect the packing process and why they are essential to operational excellence.

What is Multi Head Weigher Machines

At the forefront of packaging innovation, multi-head weigher machines meet the industry's strict criteria for fast and accurate weighing.

These multi head weigher machines , also referred to as combination scales, are integral in scenarios where precision and efficiency dictate success. Configurations vary from 10 to 24 heads, with each channel boasting an individual load cell to guarantee meticulous accuracy.

Multi-head weighers shine because they can weigh objects simultaneously across many heads, improving speed and precision.

With advanced algorithms and cutting-edge sensor technology, these machines can instantly change package weight for maximum accuracy.

This quick adaptation is critical for eliminating excess and increasing output, making multi head weighers crucial assets in the competitive packing business.

Key parts of multi head weigher

Each multi head weigher is an assembly of precision-engineered parts, each with a specific role that contributes to the machine's overall performance:

• Infeed Funnels: Guide the product into the system, ensuring a steady flow without jams or blockages.
  
• Top Cones: Distribute the product evenly to the feed trays, crucial for consistent portioning.
  
• Feed Trays: Transport the product to the weigh buckets, often vibrating gently to move the product efficiently.
  
• Prefeed Hoppers: Act as a staging area to regulate the product flow into the weigh buckets, maintaining a continuous feed.
  
• Weigh Buckets Hopper: The heart of the operation, where the product is weighed with pinpoint accuracy.
  
• Touch Screen (Control Panel): The interface where operators can input parameters, recall recipes, and monitor the system—essentially the machine's brain.
  
• Chutes: Direct the weighed product towards the packaging, designed to minimize blockages and maintain speed.
  
• Collating Funnels: Gather the product from multiple weigh buckets, preparing it for packaging.
  
• Discharge Gates: The final checkpoint, where the product is released into packaging after achieving the correct weight.

Each part of the multi-head scale works together to fulfill manufacturers' and customers' high expectations.

How Does Multi Head Weighers Work?

Precision and efficiency make multi-head weighers stand out in automated filling equipments, turning measuring into a science.

The Operational Mechanics of Multi Head Weighers

To grasp the workings of a multi head weigher, picture a finely tuned assembly line, each phase unfolding with precision and deliberate timing.

Every function of the multihead weighing apparatus operates under the meticulous governance of a Programmable Logic Controller (PLC).

Let's walk through the process, step by step:

1. Product Feeding: Products are fed into the multihead weighing machine by a conveyor belt or bucket elevator and rise to the dispersion system.
   
   Here, they are evenly distributed to ensure a consistent and uninterrupted flow into the weigher's core.

2. Radial Distribution: Once at the summit, the products are methodically dispersed into an array of pool hoppers.
   
   The product is guided into its hopper by a mild vibration or rotation, setting the stage for the weighing ballet.

3. Weighing Sequence: Descending from the pool hoppers, the products make their way into the weigh hoppers below.
   
   This is where the magic of accuracy happens.
   
   Each hopper houses a load cell responsible for measuring the product to a granular level of precision, ensuring each portion is just right.

4. Target Weight Achievement: In the brain of the machine, the computer system diligently monitors the weight data from each hopper.
   
   It's on the lookout for the magic number—the pre-set target weight that signifies the perfect portion.

5. Combination Calculation: Upon hitting the target weight, the system engages in a rapid-fire calculation to determine the most efficient hopper combination to release.
   
   This decision is critical for maintaining the rhythm of productivity and precision.

6. Product Discharge: With the optimal combination locked in, the selected hoppers open their gates.
   
   The product then enters the packing conduit, ending its weigher journey and beginning its route to the the customer.

How a multi head weigher calculate combinations?

A multi-head weigher's complex algorithm shows its engineering prowess. The precise symphony in these machines is silently conducted by this algorithm.

The Algorithm Explained

The process begins with the algorithm swiftly evaluating the weight in each individual hopper.

It's a digital strategist, calculating all possible combinations of hoppers that can collectively match the target weight.

The algorithm's precision is such that it can make split-second decisions, ensuring that each package reaches its weight specification with minimal deviation.

To keep the packing process efficient, the algorithm must determine the ideal combination quickly and accurately.

A Practical Example

Let's illustrate this with a tangible scenario.

Consider a multi head weigher with 10 heads tasked with packaging dried fruits, aiming for a target weight of 450 grams per package.

The machine first disperses the dried fruits into each hopper.

The algorithm then springs into action, analyzing weights and computing combinations.

Suppose hoppers 2 and 8 yield a total of 447 grams, while hoppers 1 and 9 give 452 grams.

The algorithm will opt for the combination closest to but not exceeding the target weight — in this case, 447 grams — to prevent giving away excess product.

This configuration ensures that the error stays within the acceptable margin, and the packaging speed remains uncompromised.

By carefully calculating combinations, the multi-head weigher meets the required weight and balances precision with packaging velocity.

Speed Benchmarks for Multi Head Weighers

In the intricate dance of packaging and production, multi head weighers play a leading role, with their operational speed being a critical performance indicator.

These machines are marvels of efficiency, designed to meet the rigorous demands of modern packaging needs.

Operational Speed Metrics

The speed at which a multi head weigher operates is often a reflection of its head count. 

• A 10-head weigher typically achieves a commendable 60 packets per minute, aligning with moderate production requirements. 
• Advancing to a 14-head weigher, the pace increases to a brisk 100 packets per minute, catering to more intensive operations. 
• At the apex, a 16-head weigher reaches speeds exceeding 120 packets per minute, setting the standard for high-volume environments.

The following are the parameters of common multihead scales for your reference.

Factors Influencing Speed

1. Product Characteristics: The physical attributes of the product—size, cohesiveness, and flowability—can significantly impact the speed.
   
   Products that flow freely allow for quicker cycles, while those that require careful handling may necessitate a slower pace to maintain accuracy.
   
2. Number of Heads: More heads equate to higher speeds.
   
   Each additional weigh head offers another parallel line of weighing, thus incrementally increasing the overall throughput.
   
3. Target Weight: The desired weight per packet can influence cycle times.
   
   Achieving heavier target weights may require more product to be processed and combined, potentially slowing down the operation.
   
4. Machine Configuration: The design of the weigher, including the geometry of its feeders and hoppers, is engineered for optimal product movement.
   
   A well-configured machine minimizes bottlenecks and maximizes speed.

Businesses may maximize their multi head weighers' speed by carefully regulating these elements.

Ideal Products for Multi Head Weigher Packaging

In the realm of precision packaging, multi head weighers stand out as the pinnacle of efficiency and accuracy.

These dynamic machines are adept at handling a variety of product types, especially those that are granular, sliced, rolled, or irregularly shaped.

What is a multihead weigher used for?

• Confectionery Delights: Candies and jellies find perfect harmony with multi head weighers, ensuring each sweet treat is measured to perfection.

• Savory Snacks: Dry food & seeds, and snack foods like pistachios and peanuts are weighed with remarkable precision, maintaining consistency in every pack.

• The Hearty and the Healthy: Pet foods & treats, dried fruits, and frozen items are treated with care, preserving their quality from weigher to package.

• The Morning Brew: Coffee beans or roasted coffee, a staple in homes and cafes, are packaged swiftly and accurately, keeping every morning fresh and energized.

• Gourmet Selections: Specialty items like meatballs and gourmet snacks benefit from the delicate handling and accurate portioning of multi head weighers.

The multi-head weigher matches each product type's specific features to assure product integrity and quality from start to end.

Strategies for Integrating with Production Lines

Customization is the cornerstone of integrating multi head weighers into production lines.

These machines are designed to adapt to the specific needs of each customer, ensuring a seamless transition into existing packaging processes.

Whether it's a Vertical Form Fill Seal (VFFS) machine for creating bags on the fly or a Pre-made pouch packaging machine for ready-to-fill solutions, multi head weighers can be combined with a variety of equipment to meet diverse packaging needs.

Real-World Application

For a snack manufacturer in Bangladesh, a bespoke packaging line was crafted, featuring a Z-type elevator and a stainless steel working platform leading to a 10-head weigher.

This system seamlessly transitioned into a VFFS Gusset bag packaging machine, complemented by a rotating material tray designed specifically for the efficient packaging of potato chips.

This structure was carefully built to accommodate the delicate nature of puffed potato chips and the workforce's simplicity of use.

PS: Ready to transform your packaging line with precision and ease? 

Our multi head weigher systems are custom-built for excellence, just like the bespoke solution we designed for a leading snack manufacturer in Bangladesh.

Connect with our packaging machine experts today for a quote, and let's tailor a success story for your business.

Troubleshooting and Maintenance

In the fast-paced realm of packaging, the multi head weigher stands as a testament to precision and efficiency.

Yet, even these marvels of engineering require a keen eye for troubleshooting and a commitment to maintenance to keep them running smoothly.

Navigating Common Issues with Multi Head Weighers

Troubleshooting multi head scales often means being a detective, looking for clues and piecing together solutions.

Here are some typical problems and their fixes:

1. Inaccurate Weights: Check for calibration drift and recalibrate if necessary. Inspect for product build-up in the weigh buckets and clean them out.

2. Machine Pauses or Stops: This could be due to product jams. Ensure that the product flow is smooth and that there are no blockages.

3. Erratic Weighing: Look for environmental interference like vibrations from nearby machinery or drafts. Stabilize the machine's location or recalibrate to compensate for these factors.

4. Electrical Issues: Regularly inspect wiring and connections for wear and tear. Keep the software updated to the latest version to avoid glitches.

Maintenance Best Practices

Maintaining your multi head weigher machine is not just about fixing issues; it's about preventing them.

Here are some best practices:

• Regular Cleaning: Keep the machine free of debris, especially if you're working with sticky or dusty products.
• Scheduled Inspections: Regularly inspect load cells, motors, and belts for signs of wear.
• Software Updates: Stay current with software updates, which can improve functionality and efficiency.
• Training: Ensure that operators are well-trained in both operation and basic troubleshooting procedures.

By adhering to these practices, you can extend the life of your multi head weigher and ensure it continues to contribute to your production line's success.

Selecting the Right Multi Head Weigher

Selecting the right multi-head weigher may greatly effect your output and profitability. It's about balancing your business's needs with these advanced machines.

When aligning your business needs with the capabilities of a multi head weigher, consider these essential factors:

1. Budget: Your financial plan will shape the range of weighers you can consider. Remember, the cost of a weigher is an investment in your production's future.

2. Number of Heads: The head count directly correlates with output. Assess your production volume to determine the number of heads that will deliver optimal efficiency.

3. IP Rating: The right Ingress Protection rating is crucial for durability, especially in environments prone to dust, moisture, or washdowns.

4. Weighing Range: Ensure the weigher's range is compatible with your product weights to maintain consistent accuracy.

5. Product Type: The nature of your product—be it sticky, granular, or irregularly shaped—will influence the design features you need, such as dimpled surfaces for sticky items or smooth surfaces for dry goods.

6. Speed Requirements: Your operational tempo dictates the speed at which your weigher should operate without compromising precision.

7. Footprint: Space is a premium. The weigher's size should fit within your facility without causing logistical challenges.

8. Ease of Cleaning: For compliance with health and safety standards, select a machine that offers straightforward cleaning processes.

By carefully assessing these factors, you can choose a multi-head weigher that fulfills your present demands and accommodates future expansion.

Conclusion

In the intricate dance of packaging, the multi head weigher emerges as a linchpin of precision and productivity.

Its selection is not merely a purchase but a strategic decision that echoes through every facet of your operations.

As you stand at this crossroads, consider how the nuanced capabilities of these machines align with your packaging aspirations. Should questions arise or guidance be sought, our doors are open.

Reach out, and together, let's ensure your packaging process is as seamless and efficient as the technology we stand behind.