Getting accurate and consistent weighing results requires careful attention to detail. For example, a chemical sample should never be added directly to an analytical balance. Instead, it should be weighed in a tared container.

Process weighing uses advanced controls and scales to measure and dispense precise quantities of materials into tanks, bags, or hoppers. This helps reduce waste and improve production.

Accuracy

For process weighing, accuracy is crucial to ensuring that your measurement data meets the specified tolerances. However, it’s important to remember that accuracy is not a standalone specification and is actually a combination of several specifications such as repeatability, linearity, resolution and response time.

Keeping your balance in the best location for accurate readings can help to minimize errors that affect measurement results. Ideally, your balance should be situated in an area that is protected from vibration and has minimal exposure to external factors such as temperature, humidity, and magnetic or electrostatic fields.

Careful handling of your samples and use of forceps or gloves to handle small weights can help to reduce the likelihood of fluctuations that can cause inaccurate results. Using the right sensitivity weights for your application can also help to ensure that your readings are as close to the true mass of the object being weighed as possible.

Efficiency

Weighing equipment can become inefficient if not optimised regularly. From preventative maintenance and calibration to data integration and operator training, there are many ways to improve weighing efficiency and performance.

Using anti-static bars and sample management software reduces the chance of small amounts of material being lost during dispensing. But this is not a complete solution, as even with these tools, tiny particles can get into vials over time and impact the accuracy of your results.

Process weighing systems help to make your operations more efficient by automating the material tracking process. Whether it is a payload management system that lets your machine automatically fill to its optimum capacity or a set of scales integrated with your control systems, these solutions allow you to track material without having to stop and manually count by hand. This gives your operators more time to work and also ensures consistent, high-quality batches. Plus, your data stays accurate in the case of power outages or temporary signal weakness.

Safety

Precise weighing ensures that ingredients are added in the correct order and proportion, maintaining consistency and quality. This reduces product waste and raw materials losses, and helps manufacturers maintain high standards that boost profitability.

Safe weighing practices start with understanding the chemical being measured, including its volatility, reactivity and toxicity. The appropriate PPE is worn (gloves, head cover, face mask), and specialised containment tools like fume hoods, safety cabinets and glove boxes limit exposure to harmful chemicals.

Weighing equipment must be carefully selected to suit the environment, and regular maintenance and calibration are vital to ensuring accurate measurements. Corrosion-resistant designs and materials protect sensitive instruments, while automated temperature compensation and washdown systems preserve performance in extreme conditions. Weighing equipment used in hazardous areas must be intrinsically safe, complying with standards like ATEX to prevent accidental sparks that could ignite explosive vapors or dust. Keeping the environment stable is also critical, with routine ventilation and avoidance of drafts.

Compliance

Precise weighing processes contribute to compliance by lowering raw material losses and rework. This cuts production costs while boosting profits. In addition, a high level of accuracy minimizes employee exposure to hazardous materials and prevents accidents.

Depending on the industry, specialized automated systems might be required for specific applications. For example, pharmaceutical companies prioritize weighing ingredients for manufacturing with high precision to ensure the final medication meets strict quality standards.

Another crucial aspect of ensuring compliance is regular balance validation. This involves comparing the instrument to standard calibration weights that have known calibration values. To avoid errors, it is important that the instrument and the calibration weights be in thermal equilibrium prior to a mass calibration. COOPER Instruments can provide various methods to solve your in-process weighing challenges, including utilizing weigh modules that convert tanks and hoppers into complete batch weighing systems or turning conveyor sections into checkweigh stations. We can also supply local displays with PLC connectivity, DIN rail mount units, and panel mount units.