meals for 33 000 airline passengers daily fast checkweigher

NewsMeat & Poultry,

Ready Meals5

Industrial Weighing and Measuring

Innovations in portioningAt LSG Sky Chefs, an innovative teamcontinually develops new baked goodsto delight passengers, especially thoseinbusinessclassandfirst class,withanever-changingselectionofdeliciouscre-ations. In LSG Sky Chef’s own bakery,just the right touch is required to por-tion out the pre-prepared dough to theexact weight specifications. Understand-ably,withabakingvolumeofover40000piecesdaily,portionweightisanimpor-tanteconomicaspect.

A weighty issueThus,creativemindsandartisanskillarenottheonlyinnovativefactorsinthebak-ery.Bykeepingahandleonweightcon-trol, METTLER TOLEDO manual check-weighersplayanimportantobjectiverole

Inthecateringindustry,compliancewithlegal quality guidelines is a matter ofcourse and second nature for industryemployees.Andinthestrictlyorganizedandhighlyregulatedairlineindustry,ca-tering specialists such as LSG Sky Chefsmust also adhere to extremely stringentrequirementsforpunctualityandquality.Thetiniestdeviationscancostdearly.

In order to achieve the highest qualityundertheever-presentdeadlinepressurewhile maintaining high output quan-tities, LSG Sky Chefs includes modernMETTLER TOLEDO BBA449check+checkweighers in manufacturing pro-cesses. These checkweighers meet the internal requirements for equipping the entire operation with the latest instate-of-the-artcateringtechnology.

Meals for 33 000 Airline Passengers DailyFast Checkweigher Ensures Quality

LSG Sky Chefs Deutschland GmbH provides meals for 70 percent of the

flights leaving from Munich. Just-in-time deliveries and satisfied

customers are a must in this industry. A key element for fast production

and high quality is the user-friendly BBA449check+ checkweigher.

2 METTLER TOLEDO Meat & Poultry, Ready Meals News 5

PublisherMettler-Toledo AGIndustrialHeuwinkelstrasseCH-8606 NänikonSwitzerland

ProductionMarCom IndustrialCH-8606 NänikonSwitzerland

Subject to technical changes © 02/2008 Mettler-Toledo AG Printed in Switzerland

Porti

on C

ontro

l in determining whether a product is ahigh flyer or a flop. “We can no longerimagineourprocesseswithouttheuseofcheckweighers,” explains Günter Rusch,inchargeofweighingtechnologyatLSGSkyChefsinMunich.“Inparticular,thenew BBA449check+ checkweigher is ex-tremely popular due to its clear displayandsmartfunctions.”

Clearly smart: “check” control functionA brief glance is all it takes for a clearreading of the scale display. With thesmart “check” function, the backlight-ing on the large, high-intensity displaychangescolorwhentheweightisoutsidethetolerancelimits(“traffic-light”func-tion). This eliminates the need for te-diousanalysisandlengthymentalcalcu-

lations.Theweightstatusisdisplayedasabarchart(showingthedistancetothetarget weight) and as an actual weightdeviation(forexample,“-100”).

Precision at ”Take-Away“ speed…it’s not rocket science! In the cold-dish and warm-dish kitchens of LSG Sky Chefs in Munich, speed is of theessence. Each day, employees createabout 33000 meals and the portionweights must be correct! Whether fora main dish, salad, or dessert, the BBA449check+guaranteesfastandpre-ciseportionswithits“TakeAway”func-tion. For example, salad is portionedwiththereservoironthescale.Theem-ployeeremovessaladfromthecontaineruntiltheBBA449check+displaychang-es colors, signaling that the requiredamounthasbeenreached.

Eachtimetheentireportionisremoved,thescalereturnstoitstareweightauto-matically.Thus,itisimmediatelyreadyfor the next portion to be removed,withoutrequiringthepushofabutton.Advantage:Thesaladportionbowlscanremain on the conveyor belt line. Thissophisticated function is not the onlyreason the BBA449check+ is a hit inLSG Sky Chefs operations. It is battery-

operating, it is extremely mobile andcan be set up wherever it is needed atanytime.

Hygiene – it’s serious business Contamination of food by bacteria orother pathogens must be avoided espe-ciallyintheairlineindustry!Toruleoutthepossibilityof suchemergencies,LSGSkyChefsensuresstrictcompliancewiththeapplicableinternationalstandardsforfoodsafetyandhygiene.

For production equipment, this meansthattechnicalequipmentmusthavespe-cialhygienicdesignsthatenableeasyandthoroughcleaningandpreventbuild-upofdirtandfooddeposits.Forthisreason,LSGSkyChefsputs its trust inscalesbyMETTLER TOLEDO, which are EHEDG*and NSF** certified and, with the newBBA449check+,offer thehighestcurrentstandardofhygieneinthisclass.

www.mt.com/ind-hygienic-design

“Traffic Light”Portion-Control Function on Display Red: 100 g missingYellow: 73 g too muchGreen: Portion OK

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Platform Size (mm)

240 × 300 300 × 400

Weighing range Resolution: 2 × 5000d (Weights and Measures approved) Optional: 30 000 d

12 lbs 0.02 lbs –

30 lbs 0.05 lbs –

60 lbs – 0.1 lbs

Options: Rechargeable battery, WLAN, protective cover, printer

Certificates: *EHEDG, **NSF, ***GMP-compliant, ****IP69k

3METTLER TOLEDO Meat & Poultry, Ready Meals News 5

One of the largest Bison meat processing companies in the United States asked

METTLER TOLEDO to help them to meet increasing regulatory demands in

accurate record keeping, inventory control, hygiene and fullfilling traceability.

Solutions for the Meat Processing Industry

Theboominhealthyeatingandinforma-tionontransfatshaveputconsumersonwatchforlowfat,highproteinfoodchoic-es.AccordingtotheUnitedStatesDepart-mentofAgriculture(USDA),Buffalo(Bi-son)meat is lower in fat andhigher inprotein thanhalibut, salmon, swordfishandtrout;hasthreetimesmoreironthanchicken;andhashalfoftheartery-clog-ging fatsof soy.Thishas createdan in-creaseddemandforbuffalomeatintradi-tionalgrocerystoresandrestaurants.

Raising andprocessing Bison is a costlyjob. Breeding stock, fencing and pro-cessing facilities, coupledwith thehighdemand for this premiummeathas ledtohigh selling prices. This demand hasalso produced higher regulation stan-dards from the USDA and one of thelargest Bison processing companies inthe United States came to METTLERTOLEDOtohelpmeetthosestandards.

Fullfilling higher regulations standardsRegulations now require accurate recordkeeping and inventory control for Bisonmeat.Thecustomerwasinneedofanelec-tronicsystemtoprovideaccuratedatathatcouldbearchivedand thatwouldholdupin a very harsh and demanding environ-ment.This solutionwouldalsoneed tobenetworkedoveranexistingcomputersystemandwork in conjunctionwithanexistingautomatedandproprietaryrinsingsystem.The METTLER TOLEDO representa-tive worked closely with the processingplant manager and determined that the

JagXtreme harsh environment terminal(nowreplacedwithIND780)would fitper-fectly into the existing track-railweighingsystem.Themeatisweighedwhilesuspendedfromhooksmountedtothetrack-rail.Theweights are then sent to the terminal fortrackingpurposes.Duetotheneedtoregu-larlywashtherailsystem,itwasimperativethattheJagXtremebeabletohandlewaterandingress.

Full traceabilityAdvanced reportingand recordkeepingofthe meat was also a new concern for theplant.ThenewFoodandDrugAdministra-tion (FDA) regulations for Bison requiredfulltrackingfromfarmtofreight.Thead-vancednetworkingcapabilitiesof the Jag-Basic software system (now replaced withTaskExpert™ programming tool) allowsforimmediatereal-timetrackingoftherawmaterialsinprocess.Theprocessingplantisnowabletorecordlivehotandcoldweightswhichimprovedthequalitytrackingofthemeatandtheinvoicingweightforcustom-ers. The previous procedure for trackingtheseweightswasmanual;thissystemwastediousandallowedforuser-errors.ThenewelectronicsystemalsoprovidesahistoryandtrackingforbothinternalandFDAregulatedreports.Theincreaseindemandandbusi-nessalso required theprocessingplant tomonitormore closely the time theprocesstookfromstarttofinish.Regulationsalsore-quiredstricttrackingofproductinandoutofthefacilities.Thisnewnetworkedsystemalsoallowedsupervisorstowatchtheoperationsin real timeand identifyareasofproduc-tioncongestion.Theoutgoingproductwas

logged through theuseof barcoded labelswith consecutivenumbering.Thisbarcod-ingsystemalsoreducedoperatordatadelaysanderrors.

The total integration of this systemtook the customer from an almost fullymanual operation to a fast-paced plantthat produces the majority of the Bisonmeat sold throughout the United States.Bison continues to grow in popularity inboth restaurants and grocery stores andleanBisonwasrecentlyaddedtotheAmeri-can Heart Association’s Eating Plan forHealthyAmericans.

Dustproof and suitablefor cleaning with high-pressure equipment

Key Features: IND780 Advanced Weighing Terminal

• Housing: Stainless steel, IP69k • Keyboard: 30-key tactile keyboard with numeric keypad,

navigation keys, function keys • Display: Backlit LCD graphic display; 320 × 240 pixels;

QVGA, 145 mm; monochrome or active TFT color • Mounting options: Panel, desk, wall • Suitable platforms/weigh modules: Up to 4 analog per

channel, POWERCELL®, MTX®, IDNet Scale, X-Base SICS • A/D rate: Greater than 366 Hz internal • Digital Input/Output: Maximum 40 inputs,

56 outputs with internal and external I/O options • Interfaces: Serial, Digital I/O, A-B Remote I/O, Profibus L2 DP,

ControlNet, Ethernet/IP, Modbus TCP, DeviceNet, TaskExpert • TaskExpert™ flow-chart based development tool


Food Safety and Accurate Weight Supported In One Step

The Spanish poultry farming and processing company AVICU successfully

combines weighing with food safety.

AVICU sells over 80% of their productsthroughretailchainsandhasan8%mar-ketshareforfreshpackedchickensand2%ofcookedchickenproductsinSpain.AsaBRCandIFScertifiedcompanyfulfillingfood safety requirements suchas trace-abilityisessential.

Successful collaborationAVICU has worked with METTLERTOLEDOSpainformanyyears.Thelong-lasting relationship originates fromthreepillars.• Consulting:METTLERTOLEDOproduct

andsystemspecialistssupportAVICUindeterminingthebestsolutionforcost-ef-ficientlymaintainingproduction,qualityandregulatoryrequirements.

• Solutions:METTLERTOLEDOistheonesourceforallweighingrelatedproducts,software,engineeringandsystemsneed-edtomeetAVICU’sspecificrequirementsofhygienic design, ruggedness, trace-abilityanddataintegration.

• Services: Fromcalibration,preventative

Solu

tions

for H

arsh

Env

ironm

ent

maintenanceuptosystemsupportMET-TLERTOLEDOservicesensureconsistentuptimeandcompliance.

AVICUconfirms:“METTLERTOLEDOpro-videsprecise, long-lastingscales, excellentsoftware systems and services. The verysmooth relationshipwith theproductandsystem specialists, who always try to un-derstand and “feel” our needs, is one ofthemainreasonswhywelikeworkingwithMETTLERTOLEDO.”

In 2006 it was time to renew parts ofAVICU’s order preparation system. AVICUsells packed poultry products in pre-commissioned plastic boxes. METTLERTOLEDOwasaskedtomodernizethelabel-lingandboxweighingsystemafter ithadbeen working without any problems formanyyears.Thesoftwarehadtobeupdatedandtheweighingterminalsreplaced.AVICUstates:“After speakingwith theMETTLERTOLEDOsystemspecialists,wenaturallyhadtoconsiderthemastheyprovidedexcellent

Vehicle scale for fast and precise accountingfor incoming and outgoing goods

METTLER TOLEDO Safeline® metal detector helps to guarantee food safety

METTLER TOLEDO solutions at AVICU, Guadalajara (Spain):

Receiving SlaugtheringCutting/Portioning

SpiceRoom

Cooking PackagingOrderPreparation

Shipping

1. Receiving/Shipping • Vehicle scale • Bench and floor scales for goods-in/-out weighing

2. Spice Room • Software based recipe weighing system

3. Packaging • METTLER TOLEDO Safeline® metal detectors

4. Order Preparation • Box weighing, labeling and data integration into MES


softwareandhardwarewhichmetourneedswithregard to the integrationofdataandfoodsafety.”

Box weighing for harsh environmentThe three recently installed box weigh-ing stations at AVICUare equippedwithMETTLER TOLEDO ID30 industrialweighingPCs,PBA430weighingplatform,labelprintersand software fordatapro-cessing.ID30isaruggedindustrialweigh-ingterminalandhigh-performingPCinonesolution.Topefficiencyandhighflex-ibilityarebundledinacorrosion-resistantstainless steelhousing, fully IP69kpro-tected forhighpressurewashdownpro-cedures.The terminal comprisesanele-gantlyflatscreendisplaywithanintuitivetouch screen human-machine-interfaceandaseparatecomputer-unit.

Weighing platforms used in hygienicallysensitive areas need to be cleaned easilyespecially if theyare installed indifficulttoreachplaceslikeunderaconveyorbelt.ThePBA430weighingplatformfulfilsthesepremises: First of all with a hermetically

sealed stainless steel load cell, IP68 andIP69kprotected forprolonged submersionandhighpressure cleaning,and secondlywithahygienicallydesignedconstructioninaccordancewiththeEHEDGandNSFguide-linesforuseinhygienicallysensitiveareas.

Data integration made efficientlyBoxes arriving over a conveyor belt areidentifiedfortareweightsubtraction.Outoffiveboxcategoriesoperatorsareselect-ingtherightone,netweightisdeterminedandassociatedwithproductdata.Thesoft-warewrittenbyMETTLERTOLEDO sys-temspecialistsprovidesthecorrectbatchnumber and expiry date associatedwiththeproductsinsidetheboxandprintsoutlabels including net weight. The systemreceives data from thehigher-levelMESand returns data back to it. AVICU un-derlines: “With thenew softwareweightdata, batch numbers, and expiry dateare amongothers stored ina SQLdata-base. If a problemwith theMES systemoccurredinthepast,thiscausedstoppageofthewholeprocess.Now,whenthesystemis down, the boxweighingactivities cansimplycontinueindependently.”

METTLER TOLEDO Safeline® metal detector helps to guarantee food safety

AVICU’s key benefits Scales are important identification points to collect traceability data such as product IDs, weight values, batch numbers and for clear labeling of products and boxes. AVICU: “Due to the excellent consultancy and system support the conjunction between

• precise net weight determination for billing reasons• traceability data and • maintaining food safety by using hygienically designed equipment is succeeded.

We like to work with a competent supplier of latest, innovative weighing equipment and software, which runs on top of that a competent service organization with fast reac-tion times.”

ID30 PC weighing terminal with label printer and data processing software

Box weighing installation with IP69k protected weighingterminal and PBA430 weighing platform

EHEDG: European Hygienic Engineeringand Design GroupNSF: National Sanitation Foundation (US)

Dustproof and suitablefor cleaning with high-pressure equipment


Properties IND469rem and KA3s/KA6s

• Integrated remote application for network operation with FreeWeigh.Net®

• For monitoring finished packs with net filling quantities of: 5g–3000g (KA3s: 0.1g Weights and Measures approved) 10g–6000g (KA6s: 0.2g Weights and Measures approved)

• Stainless steel housing

• Waterproof and dustproof IND469rem: in line with IP69k KA3s/KA6s: in line with IP66/IP67

• RS232, PS/2, Ethernet or WLAN connection

Stat

istic

al Q

ualit

y Co

ntro

l Statistical Quality ControlThe Highest Precision for Wet Areas

Special measuring instruments are needed for quality control in environments with strict hygiene require-

ments. With the network-capable IND469rem terminal and the KA3s/KA6s scales, METTLER TOLEDO

has the ideal weighing system for connection to the FreeWeigh.Net® quality control software. These devices

are made of stainless steel and are a great way to meet high-precision and strict hygiene requirements.

FreeWeigh.Net® – Quality control in a networkMoreandmorecustomersaredemandingnetworkedqualitycontrol for theirprod-ucts, i.e. centralmonitoringandevalua-tionof fillingquantitiesaswellasotherimportqualityattributes.WithitsPC-basedFreeWeigh.Net®StatisticalQualityControlsystem,METTLERTOLEDOoffers an ef-ficient solution for this demanding task.AndwhentheIND469terminaliscoupledwiththeKA3sorKA6splatforms,thisoffersqualitycontrolinwetareas.

Maximum IP protection and simple cleaningThe IND469rem terminalhas beende-signed tocomplywith the latestEHEDGandNSFhygiene designguidelines andis therefore ideally suited foruse inwetareas.Itisbothdustproofandwaterproofin line with IP69k (DIN40050) and itsextremelyfinestainlesssteelsurface(Ra<0.8µm)makesitabreezetoclean.

Network connection is hygienic and saves costsThe terminal is connected to theFreeWeigh.Net®networkviaanEthernetinterface or simply and cheaply withouttheneedforcablesviaWLAN.


0.1 g Weights and Measures approved resolution for the strictest hygiene requirementsWithitsKA3sandKA6sscales,METTLERTOLEDO has set new standards in thefieldsofwaterproofanddustproofweigh-ingplatforms.Thanks to its IP66/67de-greeofprotection,theweighingplatformcanbe rinsedwithwaterwithabsolutelyno issues.WithaWeights andMeasures

approved resolution starting from 0.1g(notWeightsandMeasuresapprovedfrom0.01g),thesedevicesaresuitableforawiderangeofapplications.Scalesthatareusedforfilllevelmonitoringoffinishedpacksaresubjecttolegalstipulations.Toensurethat labeling regulations are observed,the KA3s/KA6s platforms allow finishedpacks tobeweighed inwetareas for thefirsttimewithnetfillingquantitiesstart-

What you stand to gain

• Net weight monitoring from 5g in wet areas thanks to 0.1g Weights and Measures approved resolution

• Time-saving and thorough cleaning thanks to – IP66/IP67/IP69k degree of protection – Complies with EHEDG und NSF hygiene guidelines

• Complies with finished pack regulations

• Saves unnecessary overfilling costsEHEDG: European Hygienic Engineeringand Design GroupNSF: National Sanitation Foundation (US)

Net weight monitoring with filling quantities starting from 5g

Test placeProduct 4

Central database

Test placeProduct 3

Ethernet

Test placeProduct 2

Test placeProduct 1

For more informationwww.mt.com/ind-meat-ready-meals

Your METTLER TOLEDO contact:

USAMettler-Toledo, Inc.1900 Polaris ParkwayColumbus, OH, 43240Tel. (1) 800 523 5123

CanadaMettler-Toledo, Inc. 2915 Argentia Road, Unit 6Mississauga, Ontario, L5N 8G6Tel. (1) 905 821 4200

Mettler-Toledo AGSales InternationalCH-8606 GreifenseeSwitzerlandTel. + 41 44 944 22 11

GARVENS

SAFELINE

Breadth of experience, depth of capability

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1.ID30PCWeighingTerminal2.StatisticalQualityControl/StatisticalProcessControlBrochure3.WeighingSolutionsfortheFoodIndustry4.IndustrialWeighingCatalog2008

Share our KnowledgeLearn from our specialists – our knowledge and experience are at your

disposal in print or online.

Visitourwebsitetofindoutmoreaboutoursolutionsforthemeat,poultryandreadymealsindustry.Youcanfindinformationonawiderangeoftopicstoimproveyour

processes,includingcasestudies,applica-tionstories,return-oninvestmentcalcu-lators, plus all the product informationyouneedtomakeaninformeddecision.

1.Lowprofilefloorscalewithliftingdevice:PUA5792.Vehiclescales

A Wide Range of Solutions to Improve Processes

21

meals for 33 000 airline passengers daily fast checkweigher

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