NewsWeighing and Analysis in the Laboratory

3Machinery Plastics

Electronics

Precise Weight Determination Micro-components made out of fine plas-tics, metal or ceramics powders can be produced using powder injection molding techniques. The components produced may appear to be identical, but often weigh slightly differently. The differences can be subject to production tolerances or the machines or staff involved in pro-duction. The average piece weight must therefore be determined with extreme ac-curacy using a suitably precise balance. For this reason it is important to know whether the balance in-use is suitable or if it should be replaced with an appropri-ate one.

Modern powder injection molding processes require professional in-pro-

cess controls, particularly when manufacturing technically demanding

components. Good Weighing Practice™ (GWP®) prevents measurement

errors and ensures the quality of the powder injection molded parts

within the context of in-process controls.

Professional In-Process ControlsRelies on Correct Balance Choice

GWP® for Practical Decision Making AdviceThe first stage of any GWP® consultation process involves determining the average individual weight per shot and machine. For example, in metal injection molding application, a variation of ±0.2% might be determined per shot with a confidence factor of 95%. In this case, the mean weight of the average individual part is 0.082243 g. The more the individual val-ues of the parts being counted vary in relation to the mean, the greater the prob-ability of an error occurring if an unsuit-able balance is used.

During the second stage of the process, GWP® specialists formulate the require-ments of the weighing process, such as

Micro-components used in a camera for automatic focus function.

2 METTLER TOLEDO Machinery, Plastics & Electronics News 3

Publisher Mettler-Toledo AG Laboratory Division Im Langacher CH-8606 Greifensee, Switzerland

Production Segment Marketing LABSwitzerland

11794468 40.12

Subject to technical changes. © Mettler-Toledo AG 02/09 Printed in Switzerland.

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the importance of the measurement, the desired confidence factor or the potential possible errors due to users, environment and technology. In addition, customer requests are considered regarding issues of ergonomics, user-friendliness and the investment framework.

During the third and final stage, the typi-cal minimum initial weight of the bal-ance used is recorded on-site using an accredited procedure in compliance with ISO 17025. This includes determinations of measurement uncertainty and mini-mum weight. These values are compared and checked against the results obtained from the GWP® analysis.

The above analysis may reveal, for exam-ple, that a semi-micro balance is required to meet the minimum requirements for in-process controls. Excellence XS or Ex-cellence Plus XP balances not only ensure compliance with the required minimum initial weight of ≤0.082243 g, but are also sturdy and easy to operate. They offer ex-cellent measuring performance and sta-bility (even when subjected to the heavy vibrations caused by injection molding machines in the vicinity), providing the perfect basis for optimal in-process con-trols.

Competitive Advantages with GWP® In a best-case scenario, existing balances may be further operated without any changes having to be made. However, the GWP® consultation process often reveals that the entire weighing process can be further optimized. A traceable, risk-based analysis for a company’s quality system is produced along with valuable informa-tion for the control of inspection, measur-ing and test equipment.

GWP® customers have the advantage above competition within the global in-jection molding industry. The high level measurement quality provides a powerful sales case for winning over end custom-ers.

} www.mt.com/gwp

Good Weighing Practice™ is a guideline that offers improved control over your entire measuring process. Weighing recommenda-tions can be specifically tailored to quality requirements, risk and industry regulations. Employees will immediately profit from the greatly simplified testing procedures which are designed to save time and costs. Secure and traceable quality documentation is also automati-cally available for auditors. Weigh without risk with GWP®. Comply easily with regulations and realize consistent high product quality.

3METTLER TOLEDO Machinery, Plastics & Electronics News 3

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New ISO Standards

In order to achieve higher efficiency when carrying out quality tests,

the Japan Rubber Manufacture Association aims to establish moisture

determination with the halogen drying method as laid out in the new

ISO standard. METTLER TOLEDO’s expertise provides the most suitable

method.

High Tyre Requirements The tyre production industry is one of the largest consumers of natural and synthetic rubber. The safety and quality of tyres are strictly regulated and all raw materials must undergo several quality tests. The ISO248 International Standard specifies two methods for the analysis of moisture and other volatile matter con-tents in raw rubber: the hot mill method and the oven method. Both are labour in-tensive and times consuming which was reason enough for the Japan Rubber Man-ufacturers Association (JRMA) to evalu-ate alternative determination methods. With METTLER TOLEDO, JRMA found the technical support and expertise in mois-ture analysis they were looking for.

Faster to the Finish Line with Halogen DryingMoisture in natural and synthetic rub-ber is very low, i.e. <1% moisture content

(typically 0.20–0.40% MC) and reproduc-ible results are difficult to obtain. Test series with Halogen Moisture Analyzers have shown that the same results can be obtained as with the reference method in the oven. Measurement time, however, is significantly five times shorter. METTLER TOLEDO instruments function efficiently and accurately even at the factory produc-tion site where they can be easily cleaned from carbon black and other particulate materials. JRMA is convinced that its members will appreciate the implemen-tation of an efficient and cost-effective method for moisture determination. Their aim is to establish halogen dry-ing in the revised ISO248 and to obtain better and faster methods for the rubber industry in order to produce high quality, reliable tires.

} www.mt.com/moisture

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METTLER TOLEDO Machinery, Plastics & Electronics News 3

Time is Golden Piece Counting with METTLER TOLEDO's Solutions

The synergy of Excellence X-Platforms and Industrial Terminals is per-

fectly employed by one of Geneva’s world famous watchmakers who uti-

lize the advantages of the IND-Terminal’s robustness along with the high

resolution and performance of precision balances. METTLER TOLEDO’s

tailored solutions guarantee the highest accuracy in industrial applica-

tions.

Piece Counting with Absolute ReliabilitySituated in the vicinity of the Plan-les-Ouates industrial zone in Geneva, Swit-zerland, Meroz is a partner of the world’s most prestigious Swiss watchmaker de-livering springs, wheels, cogs and other delicate components. In order to portion the pieces prior to packaging, Meroz uti-lizes the piece counting application of METTLER TOLEDO’s Precision Balances.

The X404SDR and X64001L platforms have been connected to the IND690 ter-minal, which is flexible enough to simul-taneously control up to four balances. An X404SDR Precision Balance is used as a reference balance. A few pieces are first counted by hand and used as a refer-ence. Subsequently they are transferred to the 64 kg capacity X64001L Platform Balance. Finally, larger quantities are placed onto the weighing pan. The weight is expressed as the number of pieces in the weighing pan. This same measure-ment application has been installed into the automatic storage facility of their neighbouring production facility. Pieces produced and/or delivered by external suppliers are weighed, counted, portioned and routed via a conveyer belt for watch assembly.

METTLER TOLEDO is the Name for QualityWhen employing the piece counting ap-plication, repeatability is crucial. Reliable results and high performance are prereq-uisites as some watches are assembled from solid gold components. Both stabil-ity and robustness are also required for

this industrial environment (IP protec-tion 69K). Software packages built into the terminal support nine different ap-plications invaluable for counting, fill-ing, check-weighing and formulation etc. Both IND-terminal and X-balances are also available as ATEX Zone 2 versions which are applicable for hazardous areas (category 3G).

Weighing pieces instead of individual manual counting speeds up the whole process enormously and reduces human error which, in turn, reduces costs.

The industrial terminal offers intelli-gent process monitoring. In combination with the precision of the Excellence X-Platforms, (210 g to 64 kg capacity and 0.1 mg to 1 g readability), they offer un-surpassable benefits for a wide spectrum of industrial processes. Trust METTLER TOLEDO’s tailored solutions for precise applications to count even the smallest pieces with absolute reliability!

The watchmaker of Geneva claims that METTLER TOLEDO’s name is synony-mous with quality.

} www.mt.com/x-platform} www.mt.com/x-ind

IND Terminal

5METTLER TOLEDO Machinery, Plastics & Electronics News 3

DSC Cost Reduction in Vehicle Construction

Using DSC for Plastics Testing

In the last few decades, plastics have become an indispensable material

for constructing new vehicles. Its versatility has meanwhile penetrated

practically every element of a car. In order to guarantee a consistent high

quality, it is appropriate to perform efficient tests from goods receipt

right up to the finished part. Dynamic Scanning Calorimetry (DSC) has

efficiently accompanied the development and quality management of

plastic products for many years.

Plastics can be found everywhere: from the engine to the body and interior. It is important for the manufacturers to make sure that the quality is high and consistent as rejects or even the re-call of a whole vehicle series due to a single component defect may incur immense financial and reputation costs.

The exterior shell of a polyamide 12 (PA12) hydraulic line exhibited a small discoloration defect and it was important to clarify whether this was due to a for-eign substance or a changed PA12 poly-mer matrix. The defect was removed from the line with a scalpel. The sample weight was measured as 3.135 mg. The analy-sis applying DSC1 and STARe software revealed an additional melting effect at approx. 205 °C in both the first and the second heating processes. Such an effect was not found in the other areas of the part. This clearly indicates that a foreign substance was present which exhibits a melting effect at 205 °C. The temperature level, where the effect occurs, suggests that the substance is a polyamide 6 (PA6) that accidentally entered the production process.

This example demonstrates that even the smallest measuring effects, caused by minute sample quantities or weak, ther-mally induced changes can quickly be detected and dealt with using the state-of-the-art DSC sensor technology from METTLER TOLEDO.

} www.mt.com/ta

Due to the reduced weight compared to metals, the emission of climate-damag-ing CO2 is clearly lower, plastics do not oxidize and are mostly recyclable and safety belts, airbags and child seats all make everyday's life safer.

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METTLER TOLEDO Machinery, Plastics & Electronics News 3

One Click Titration™Powerful System for the Labs

The Titration Excellence line combines application flexibility with the

optimally efficient operation in titration. This satisfies the requirements

of an innovative company like Blaser Swisslube exactly. The most de-

manding applications are made quick and simple using LabX titration

PC software.

Powerful Evaluation Saves TimeBlaser Swisslube is a worldwide operat-ing company and a leading producer of lubricants and cutting fluids for the met-al working industry. The quality control laboratory carries out titration analyses such as TAN, TBN, saponification num-bers and many more. Due to the large sample variety and complex composition, each individual analysis requires a differ-ent evaluation. The METTLER TOLEDO Excellence Titrators offer a new algorithm which also recognizes weak equivalence points. Thomas Schmid, head of quality control, is thrilled. “In the past we had to find the equivalence point of many titra-tion curves manually. The T90 Excellence Titrator now also recognizes very weak in-flection points. This saves us a lot of time and strongly increases the reliability of our results.”

Obviously there are still a few titration curves that are impossible to evaluate automatically. In this case, the curve is opened in the PC software LabX Titra-tion and the result is found by graphical re-evaluation. The unique dual mode al-lows the user to work with both the touch screen terminal at the titrator and with the PC ‘LabX Titration’ software ‘LabX Ti-tration’. Analyses can be quickly initiated directly from the titrator and curves can be checked in LabX Titration. This makes working with the system far simpler. PowerShower™ Prohibits Sample Carry-overThomas Schmid’s team usually runs three determinations of the same sample and efficiency is further improved by us-ing the Rondo 60 Sample Changer. The three samples are placed on the sample changer rack and the analysis is started with a single click. Other sample series are

Quick Base Numbers (BN) The IP400 standard specifies conductivity titration to determine the BN of lubricants. Using the Conductivity Board integrated in the Excellence Titrator, a BN deter-mination is completed three times faster than common potentiomet-ric applications. Blaser Swisslube achieves the same results with far less maintenance.

analyzed immediately afterwards. Due to the PowerShower™ rinsing unit, sample carry-over is prevented therefore provid-ing consistently accurate results.

By using the new Excellence Titrator T90 with LabX Titration and Rondo 60 Sample Changer, Blaser Swisslube has made titra-tion far simpler and more efficient in their laboratory.

} www.one-click-titration.com} www.mt.com/labx

Titration Excellence System and LabX Titration Software

7METTLER TOLEDO Machinery, Plastics & Electronics News 3

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ces Particulate Matter Measurement for

Diesel Engines

Diesel engines have been becoming popular due to their economical ad-

vantage whilst emitting less CO2 than gasoline engines. However, diesel

engines have the disadvantage of emitting more NOX and Particulate

Matter (PM). Reducing the PM emissions from diesel engines is the big

challenge for the automotive industry.

Filter Weighing with Micro BalanceGravimetric PM filter measurement with a microbalance is an established measure-ment method. As defined by strict regu-lations in respective countries, it is the only method which realizes both direct traceability and calibration. Due to the stringent emission amount of 0.1 g, an ultra micro balance is necessary to meet requirements.

The new filter weighing kit for the MX/UMX Balance from METTLER TOLEDO is the best solution to meet these require-ments. Two weighing pan sizes (for 47 mm & 70 mm) are included and filters are al-ways weighed in the ideal position. The robust stainless steel housing eliminates air turbulence and heat transfer, there-fore ensuring a faster stabilization time and better weighing performance. The automated draft chamber and SmartSens (Infrared sensor on the terminal) per-form the operation without touching the balance – a combination that makes the measurement in the glove box much eas-ier and safer than ever. The draft chamber can be opened on the left or right side depending on the dominant hand of the operator.

Complete Filter Weighing ApplicationMETTLER TOLEDO has a comprehensive software solution for storing all measure-ment data even when measuring numer-ous filters per day – LabX. LabX Software can not only deal with unlimited number of filters, but also ensure perfect data traceability. LabX can create ‘weighing methods’ according to the workflow. The weighing procedure is fully guided via pop-up dialogues on the balance display – the operation can be carried out without handling a PC. LabX can also export data to EXCEL on demand for flexible data evaluation.

} www.mt.com/micro

UMX2 Microbalance

XP505 ComparatorPeak Performance up to 520 gThe new XP505 Comparator offers 520 g capacity with unique 0.01 mg readability over its full range. It allows to weigh into heavy tare containers, determine smallest weight differences of heavy goods or determine the weight of tiny electronic parts. The intuitive touchscreen display and hand-free operation make it the first choice for demanding applications in the metal & electron-ics industry.

} www.mt.com/comparators

One ClickTM Water DeterminationSimple & SecureWater determination is made simple and secure with the new line of Karl Fischer titrators offering unique Touch Screen operation with user specific Short Cut buttons. Every user can start his or her routine tasks with One ClickTM. The Solvent Man-ager is controlled by the titrator and exchanges the solvent and reagents without exposing the user to chemicals. A wide variety of samples is covered by Volumetric and Coulometric titrators and gas-phase extraction ovens.

} www.mt.com/Karl-fischer

Meeting Emissions StandardsWith Minimal CostsDetermining the weight of particulate matter is a key task in the automotive industry. F-A747 Filter Robot allows fast and easy measurement of par-ticulate matter at any time. Up to 60 samples can be read in via barcodes. All steps from the start right up to residual weighing are performed auto-matically, quickly and without the slow process of transferring samples.

} www.mt.com/filter

LabX Balance Software Version 1.5 New: Inbuilt Job Templates and GWP® Support!In this new version of LabX balance software, 25 ready-to-use job templates are integrated. It is even easier to get up and running with applica-tions such as Moisture Content Determination, Filter Weighing, Standard Solutions, Density Determination and many more! Using the full on screen user guidance, on both balance and PC, LabX balance 1.5 also helps you work according to GWP® guidelines, making lab work easier and more efficient. } www.mt.com/labx-balance

Mettler-Toledo AGLaboratory DivisionIm LangacherCH-8606 Greifensee, Switzerland

Your METTLER TOLEDO contact:

www.mt.comFor more information

Weighing Solutions and Analytical Instruments

New Products and Technologies From METTLER TOLEDOMETTLER TOLEDO delivers powerful solutions that simplify work in labo-

ratories around the world. Combining our state-of-the-art technologies

with our applicative competence, we have a strong value proposition to

make: accurate results and productivity second to none.