Bottle Check Weigher Machine
High-precision in-motion dynamic checkweigher operating up to 300+ containers per minute with ±0.05g accuracy, real-time Statistical Process Control (SPC), and automatic pneumatic rejection.
Description & Operating Principle
HMEC’s Dynamic Inline Bottle Check Weigher is an essential quality assurance system designed to verify the exact fill weight of every bottle, vial, jar, or carton in continuous motion. In pharmaceutical, cosmetic, and chemical packaging, even minute dosing errors lead to either illegal underfilling or costly active pharmaceutical ingredient (API) giveaway.
The system consists of three synchronized conveyor zones: an infeed pacing conveyor to space bottles individually, a ultra-responsive Electromagnetic Force Restoration (EMFR) weighing platform, and an outfeed sorting zone. Advanced DSP (Digital Signal Processing) algorithms eliminate ambient conveyor vibrations to capture milligram-accurate weight values in milliseconds. Containers outside programmable upper or lower limits are instantaneously segregated by high-speed air-blast, pusher, or drop-down gates into lockable reject bins.
Target Products & Applications
Dynamic checkweighing provides quantitative validation across various packaging formats:
🧴 Liquid Syrup & Suspension Bottles
Verifying exact fill volume in PET, HDPE, and glass bottles from 15ml to 1000ml.
💊 Solid Dose Tablet & Capsule Bottles
Detecting missing tablets, missing cotton plugs, or missing desiccant bags in counting lines.
📦 Secondary Cartoned Packaging
Catching missing patient information leaflets (PIL), missing dosing spoons, or empty blister pockets.
🧪 Dry Powder & Injectable Vials
High-precision micro-gram level tare/gross checkweighing for sterile injectable vials.
Pros & Cons Comparison
✅ Advantages (Pros)
- 100% In-Line Verification: Weighs every container in continuous motion without reducing packaging line speed.
- High Precision (±0.05g): EMFR technology delivers laboratory-grade repeatability on fast industrial conveyors.
- Automated Feedback to Fillers: Optional closed-loop feedback automatically adjusts upstream filling nozzles/pistons.
- Statistical Process Control (SPC): Displays live histograms, standard deviation, running average, and batch yield metrics.
- 21 CFR Part 11 Compliance: Multi-level user access, encrypted audit trail, and USB/Ethernet report export.
⚠️ Considerations & Limitations (Cons)
- Vibration Isolation Crucial: Must be installed on a sturdy, vibration-decoupled foundation away from heavy air compressors.
- Consistent Product Spacing: Requires infeed timing screws or side-grip belts to prevent containers touching on the weighbridge.
Type & Range of Check Weigher Systems
On basis of product weight
- ✅ Ultra-Fine Micro Checkweigher (Up to 200g, ±0.01g)
- ✅ Standard Bottle Checkweigher (Up to 1500g, ±0.05g)
- ✅ Heavy Duty Shipper Case Checkweigher (Up to 25kg)
On basis of rejection mechanism
- ✅ Pneumatic Air-Jet Blow-Off (For light vials/ampoules)
- ✅ High-Speed Cylinder Pusher (For syrup bottles/cans)
- ✅ Drop-Down Flap / Diverter Belt (For fragile cartons)
On basis of combination features
- ✅ Standalone Dynamic Checkweigher
- ✅ Checkweigher + Metal Detector Combo System
- ✅ Checkweigher + 2D Serialization Camera Unit
- cGMP compliant AISI 304 stainless steel structure with sanitary food-grade conveyor belts
- High-speed German/Swiss EMFR load cell ensuring exceptional dynamic weighing stability
- Real-time Digital Signal Filtering eliminating line vibrations and draft disturbances
- Tool-less quick belt removal mechanism for rapid cleaning and belt sanitization
- Color 10-inch touchscreen HMI with graphic display of weight distributions and standard deviation
- 3-zone or 5-zone weight sorting (Underweight, Target Weight, Overweight)
- Lockable stainless steel reject bin with reject confirmation sensor and bin-full alarm
- Complete 21 CFR Part 11 compliance with audit trails, user logins, and password protection
- Ethernet, USB, and RS485 connectivity for SCADA / MES line integration
- Backed by 40+ years of precision packaging engineering and turnkey line support
| Weighing Range | 10 g to 1500 g (Custom load cells available up to 6000 g) |
|---|---|
| Weighing Accuracy | ±0.05 g to ±0.1 g (Product size, shape, and conveyor speed dependent) |
| Output / Speed | Up to 150 to 300+ Containers Per Minute (CPM) |
| Weigh Cell Type | Electromagnetic Force Restoration (EMFR) or High-Speed Digital Strain Gauge |
| Belt Dimensions | Weigh Belt Width: 100 mm to 250 mm | Length: 200 mm to 350 mm |
| Reject Mechanisms | Pneumatic Air Blow-Off, High-Speed Cylinder Pusher, or Drop-Down Chute |
| Control Architecture | Dedicated High-Speed Microprocessor / PLC with 10" Color Touchscreen HMI |
| Data Export & Audit | USB Data Export, Ethernet TCP/IP, 21 CFR Part 11 Audit Trail |
| Power Supply | 220 V AC / Single Phase / 50-60 Hz (Approx. 0.8 kW) |
| Compressed Air | 5 to 6 Bar Clean, Dry Compressed Air (50 - 100 L/min) |
Format Adjustments & Tooling
HMEC Checkweighers are built with tool-less adjustment features to switch between bottle sizes in under 5 minutes:
- Infeed Guide Rails: Quick-lock handwheels adjust conveyor guide width for containers from 20 mm to 120 mm diameter.
- Reject Pusher Height: Vertically adjustable to strike the container center of gravity and prevent tipping.
- Recipe Selection: One-touch recipe recall on the touchscreen updates target weight, tolerances, belt speeds, and reject timing automatically.
Frequently Asked Questions
Q: How does a dynamic checkweigher handle conveyor vibrations?
A: HMEC checkweighers employ specialized digital DSP filters that sample the signal at high frequencies and filter out mechanical motor frequencies, capturing the true static weight value even at high conveyor speeds.
Q: Can it detect a missing instruction leaflet inside a carton?
A: Yes. With ±0.05g accuracy, the system easily detects the weight absence of a single 60 GSM folded leaflet (typically weighing 1.5g - 3.5g).
Q: Does it meet 21 CFR Part 11 requirements?
A: Yes. The control system features individual operator logins with password aging, encrypted audit logs, automatic logout, and unalterable PDF batch report generation.