Weighing processes are crucial for the quality of many products and manufacturing operations. Whether you focus on consistent product quality, lean manufacturing or regulatory compliance, your weighing process must be accurate and repeatable.

Balances (also called beam balances or laboratory balances) use two pans to balance known masses against unknown ones to provide a measurement of mass. They can measure in different units of mass depending on the application.

Level Measurement

Level measurement helps determine how much of a product is in a storage tank, silo or container. It allows manufacturers to maintain optimal production conditions by avoiding empty or full tanks, reducing inventory costs and eliminating waste.

A variety of level measurement technologies are available, ranging from manual or mechanical (floats, sight glasses and tape levels) to radar, ultrasonic, capacitance or laser. Using the right technology for the job is critical, as a failure to do so can lead to inaccurate data that causes costly delays in production.

For mobile tanks or single-use vessels, such as bioprocess bags, the need for versatility can further complicate the choice of level measurement technology. These containers often contain a mix of liquids with differing properties like viscosity, temperature and dielectric constant, so they require sensors that can adapt to these changing conditions. Capacitance type sensors are a great solution to this challenge due to their simple design and corrosive resistant probes.

Inventory Measurement

In addition to speeding up production times, precise weighment reduces raw material losses and rework. This translates to less waste, which directly impacts bottom line profitability.

Many automated systems feature pre-weighing functions that allow workers to determine the number of pieces based on container or packaging weight, eliminating the need for reference weighing before counting the entire batch. They can also automatically retrieve and log data that enables quick access to information like ingredients, product origins, or previous weighing records. This ties into inventory management, quality assurance, and predictive maintenance features.

In addition, automated weighing systems simplify onboarding for new employees. Since they are easier to use than traditional scales, staff can quickly become proficient and minimize the risk of beginner errors. This translates into reduced training time and more productive operations. This is important for companies that are inventory-obliged, as it reduces the likelihood of losing sales or tying up valuable working capital.

Dispensing

In pharmaceutical and chemical industries, where exact quantities are required, precise weighing helps reduce raw material loss and waste. This translates into higher profitability, and a positive impact on customer satisfaction.

Direct weighing involves placing a substance directly on the balance pan and measuring its mass. It’s important to make sure the balance is properly zeroed (reading zero with nothing on the balance pan) before starting the measurement.

If you’re weighing liquids that are toxic or corrosive, it’s best to dispense them away from the weighing instrument. You can do this by tareing the instrument, then placing a clean container on the scale and recording its weight. Then subtract the weight of the empty container from the weight of the filled one to get your sample size.

If a sample sticks to the weighing container, you can try flicking it lightly with your fingers while pouring or scraping it with a transfer tool (be careful not to gouge). The best way to handle this challenge is with dedicated laboratory software like Titian’s Mosaic, which offers seamless integration with liquid handlers.

Batching

The accuracy of automated weighing processes is critical. It ensures a more consistent and predictable process, and allows businesses to meet production demands faster and more efficiently. To optimize the performance of these systems, it is essential to understand current processes and identify areas that would benefit from automation.

It is also vital to select the appropriate load cell for a specific application. The load cell measures the weight of a sample through mechanical force, with strain gauges bonded to points on its surface. When a load is applied to the correct spot, it causes the cell to bend, with the gauges responding by sending a signal change proportional to the dispensed weight.

Using batching can help ensure that your team is focused on the task at hand without distraction. For example, an employee may choose to check and respond to emails only during one block of time. This helps prevent the constant interruptions and detours that can undermine productivity.