Application background and core pain points

Product line: We specialize in brewing soy sauce and viscous oyster sauce for the market, packaged in 300ml-1L glass bottles and PET bottles.

Core pain point:

Net content compliance high-voltage line: As a livelihood food, the net content must comply with 100% of the "Measures for the Supervision and Administration of Quantitative Packaging Commodity Metrology". Any "shortage of weight" will cause serious brand reputation crisis and regulatory penalties.

Challenge of filling accuracy for viscous liquids: Oyster sauce and other products have high viscosity and poor fluidity, and traditional filling machines are prone to fluctuations, resulting in inconsistent weight per bottle.

The cost black hole of "invisible": To prevent insufficient weight, companies usually set a "safety margin" for filling, leading to systematic "overfilling". Adding 2-3 grams per bottle can result in an annual loss of tens of tons of raw materials, leading to significant cost losses.

Packaging defects are difficult to detect in a timely manner: slow leakage caused by poor sealing of bottle caps, missing labels, etc., and manual sampling is difficult to effectively identify on high-speed production lines (such as 200 bottles/minute).

Lack of process data: unable to quantify production stability, difficult to implement lean management and problem tracing.

2、 Solution: Integrated online plagiarism detection and data feedback system

Deploy a high-precision and corrosion-resistant online weight inspection system at the golden workstation after "filling capping labeling" and before "packing" on the production line.

Core configuration and characteristics of the system:

High precision dynamic weighing scale:

Special anti-interference design: Advanced digital filtering technology is adopted to effectively overcome the weighing signal interference caused by liquid shaking inside the bottle, ensuring stable readings.

High hygiene level: The whole machine is made of 304 stainless steel with IP66 protection level, supports high-pressure water gun flushing, and meets food production hygiene standards.

Accuracy: The range covers 2kg, with an accuracy of ± 0.5g, and can sensitively detect small weight differences.

Non contact removal device:

Priority should be given to using air blowing for removal: clean compressed air is used to blow non-conforming products away from the main line through precisely controlled nozzles. Advantages: No physical contact with the bottle body, avoiding label scratches or bottle collisions, especially suitable for high-end glass bottle packaging.

Intelligent Control and Data System:

Formula based management: The touch screen can store the weight parameters of dozens of different products (such as "500ml Gold Label Soy Sauce" and "750ml Premium Oyster Sauce"), and can be switched with one click when changing production.

Real time SPC process monitoring: The screen displays real-time weight trend chart, average value, standard deviation, pass rate, shift output, etc.

Data closed-loop feedback (key value): The system can calculate the average weight of continuous products and feedback this signal to the upstream filling machine through analog or communication (such as Modbus TCP) to achieve automatic fine-tuning of filling volume and accurately lock the average weight at the target value.