Weighing is an important part of a number of manufacturing processes. It can be used to verify ingredients, control inventory, and improve product quality.
When using a balance, it is essential to understand good weighing practices. This includes following proper procedures and avoiding certain actions that can affect the reading.
Accuracy
There are several factors that affect the accuracy of weighing processes. For instance, vibrations can alter the weight reading if the balance is not located on a stable and level surface. Also, air currents can cause inaccurate weighing results if the balance is not properly sealed and ventilated.
The best way to avoid these errors is by following good laboratory practices and regularly calibrating the weighing scale with precision mass standards. However, even a well-calibrated system can have errors. This can be caused by a variety of factors, such as imbalance, temperature shifts, and imbalance of the load cell.
Another factor that can reduce accuracy is shock loading. While higher-capacity load cells can withstand this, repeated shock loading degrades the performance of your scale over time. It is also important to keep the weighing system as isolated as possible from other equipment that may produce mechanical vibrations. In addition, it is essential to maintain the proper humidity levels in the lab to avoid electrostatic discharge.
Reliability
Weighing is an important step in manufacturing. It ensures that ingredients are added in the correct order and quantity to create a finished product that meets set standards. This is especially crucial in sectors such as pharmaceuticals where the wrong ingredient can lead to a dangerous medication.
Weigh-in-process can be used to identify products that are out of specification, reducing defect waste and enabling manufacturers to quickly address problems before they become costly reworks or recalls. However, weighing is not always accurate, which can be caused by a number of factors including inappropriate equipment, improper installation and calibration or external forces like wind or temperature.
A key component of any digital weighing system is the load cell, which converts mechanical force (such as weight) into an electronic signal that can be read by a digital display. Four factors can affect the accuracy of a balance: response time, non-linearity, hysteresis and non-repeatability. Choosing the right weighing equipment for your application, keeping it properly calibrated and maintaining it in a clean and stable environment will improve accuracy.
Safety
Weighing dangerous chemicals requires special attention to ensure both safety and accuracy. In addition to the right weighing equipment, you must also take steps to avoid contamination and environmental conditions that can impact measurements. For example, it is important to always close the weighing chamber doors and use clean forceps when handling samples. Doing so will prevent cross-contamination and prevent the transfer of oils to the weighing pan, which can affect the readings.
Additionally, hygroscopic materials can absorb moisture, causing an increase in weight measurement, while liquids may evaporate, resulting in condensation that can contaminate the weighing pan. Finally, magnetic materials can interfere with the delicate balance components that enable accurate measurements.
Weighing systems designed to work in hazardous areas are required to comply with specialized standards like ATEX and NFPA. This certification means that they are safe to use in environments with flammable gases, vapors, or dust and that they cannot provide the energy needed to trigger an explosion.
Maintenance
Weighing in manufacturing operations is integral to quality assurance, inventory management, and reducing defect waste. However, it requires the right equipment and consistent best practices to perform at optimum levels.
Maintaining a clean, dust-free weighing area is the first step in ensuring accurate results. Use a soft brush or lint-free cloth to remove any residue from the weighing pan. This will prevent any build-up and keep the weighing system functioning properly.
Ensure the weight indicator’s input and output signals are operating correctly by examining the circuit board for damage, and checking the indicators display to confirm that it is functioning normally. Check the condition of the cables that connect the weighing platform to the indicator, and look for signs of fraying or loose connections.
Consider implementing a data and analytics solution that can capture key performance metrics and identify issues or potential problems in real-time, allowing for proactive maintenance and optimisation. This will help you improve efficiency and profitability.