Scale Service Cost Guide

American Scale Company test truck

Scale Service Cost Guide.

An accurate scale is an essential tool for any company whose revenues are based on the weight of goods entering or exiting a facility. Without scale accuracy, a company can lose thousands, if not hundreds of thousands of dollars annually. On the other hand, the annual maintenance costs for a truck scale can vary anywhere from $1,000 to $10,000 annually depending upon what services you are receiving. If you were to consider the potential cost of weighing errors, then you could see how a good maintenance program more than pays for itself, and how at times it can also pay for the cost of the scale. To make sure that your scale maintenance program is most effective, these are components that need to be present to ensure a good program. This article outlines what makes a good scale maintenance program and how much this will generally cost.  

BENEFITS OF HAVING A GOOD SCALE MAINTENANCE PROGRAM.

When setting up a scale maintenance program for your weight operation, you want to think about the long term benefits you will receive when following a good maintenance program. One of the biggest benefits is the fact that you will  have regular scheduled maintenance. Understanding that there is a maintenance program for you to follow will help you better understand your scale’s needs based on frequency of use as well as environment and other factors. When you have a good program, you inevitably build a strong relationship with the service technicians as well as with the scale company itself. Saves down time of vital equipment large/heavy scales cannot easily be transported, so techs can work onsite. Rapid response times provided to critical equipment at your facility helps save potential lost profits by cutting downtime helps you stay organized and up to date with your scale service records.

USING A STATE LICENSED SERVICE PROVIDER

When it comes to getting your scale certified, it cannot be done by a commercial scale company. The state weights and measures organization are able to do that. As long as the scale company is state-licensed and registered, they are able to perform services on your scale. The reasoning for this is because there are specific standards that need to be met according to the state weights and measures organization. Look for companies that have a good standing and provide services to multiple scales in the area. If you go with a service provider who is unlicensed then you run the risk of having improperly serviced equipment along with getting into hot water with the state weights and measures department. It is not recommended to allow a company that is not licensed to service your scale. 

USE STATE-CERTIFIED TEST WEIGHTS FOR CALIBRATION

When going with an established scale service company, they will typically have an entire inventory of test weights tested and certified annually in accordance with state weights and measures standards. They will have test weights for all manner of scales and sizes. Depending on the scale being calibrated or serviced will determine the size of the weights being used. Depending on what is being calibrated or having a load test will determine how much weight you will actually need.

THOROUGH SCALE TESTING

The test should start by determining the length of the platform and the total number of sections along that length. Load points are where weight is transferred from the load to the scale and where scale accuracy is maintained. It is critical that the accuracy of each load point is maintained, so as weight is applied it is transferred evenly.

If a load point or section fails a strain test, then it must be calibrated to conform to requirements by making a mechanical or electronic adjustment. A good scale service company will check and double check for accuracy on each load point.

VISUAL INSPECTION AND REPAIRS

Whenever there is any sort of service performed on a scale, the scale technician will perform a visual inspection of the scale. A thorough scale maintenance program must include regular visual inspection followed by any necessary repairs of issues found. The visual inspection should include scale condition, regulatory conformance, signs of damage and debris buildup, safety, clearance, corrosion, and any electrical conditions. A detailed inspection is the sign of a good scale service company. 

BREAKING DOWN THE COST

When looking at what it will actually cost to set up a scale maintenance program, you have to consider the biggest factors that will affect cost. Below are some of the factors that will affect the cost, along with an average rate that is floating around right now. Distance traveled to perform service. Travel charges are usually based upon zones from the nearest office to the service site location. Depending upon the shop performing the service will determine the overall price. Bench time can range anywhere from $125 upwards of $200 per hour depending on the service and if there will need to be additional repairs for the scale.

Additional parts or travel time depending on the issue at hand. Some scale companies will price based on “zones” instead of price mileage. When thinking about scale service and maintenance, it is good to look at it like servicing your car. If you were to take your car into a dealership or independent mechanic, then you will pay an hourly charge. In some areas, mechanics start out at $150 per hour and go up from there. The same thing can be said about scale service. A good maintenance program will be thorough, and should include a written report documenting test results including both before and after calibration, as well as a summary of finding and recommendations. All of these aforementioned items are essential to having a well documented and maintained scale.  

CLOSING WORDS

At American Scale we strive to bring you informed and useful content on all things scale systems related, including products from the top scale manufacturers. Be sure to check out our truck scale articles about Truck Scale Foundations or How Much Do Truck Scales Cost. We even have a Guide to Warranties. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' andHow Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership. Also, take a look at our“Common Problems With Bench Scales'', to help prolong the lifespan on your scale.

How Much Is An Analytical Balance?

lab balance

Analytical balances are pieces of equipment that combine the functions of both a balance and a precision scale. They are used to weigh small quantities accurately and precisely, making them perfect for businesses that deal with ingredients or other small quantities of substances frequently. Depending on your specific needs, there are three main types of analytical scales: mechanical, electronic and digital. Each type is also available in varying price points, depending on their features and functions.

An analytical balance is an important tool for any business or individual that wants to make precise measurements. This type of balance is commonly used in scientific and industrial settings to ensure accuracy. You will commonly see them in laboratories and the like. In this article we will go over the what an analytical balance is as well as what influences the cost. 


 Mechanical Analytical Balances

Mechanical analytical balances are the most accurate and precise type of analytical balances on the market. They feature extremely high accuracy, so weighing small quantities of material accurately is not an issue. However, this accuracy comes at a cost: these balances are quite large and heavy, which makes them not ideal for use in some environments. While they make sense for businesses that rely on precise measurements of ingredients, they’re not practical for smaller for independent operations. Although they’re the most accurate type of balance, mechanical analytical balances cost more than other types. They are also significantly more expensive than electronic or digital models. The main reasons they’re more expensive is due to the amount of parts needed to ensure it operates properly.

 

Electronic Analytical Balances

Electronic balances are the most commonly used type of analytical balance. They are accurate and precise, but they’re also easy to use. With electronic balances, you don’t have to worry about calibration errors or other issues that can cause mechanical balances to malfunction. These balances are also known as digital scales and come in a variety of models, sizes and price points. As long as you can find a balance that fits your budget, you should have no trouble finding the perfect balance for your needs. You can even decide whether you want a scale that features a dial, buttons or a touch screen. That will determine what features and functions are included in the scale, as well as the price. Electronic analytical balances come in a variety of styles, including tabletop and floor models, so you have plenty of options to choose from.

 

Digital Analytical Balances

Digital analytical balances are the most recent type of analytical balance to hit the market. Like electronic scales, they are extremely precise and accurate, but they’re also much more affordable. That makes them a popular choice for many businesses that need a scale but don’t have the budget for a high-end model. There are several great things about these scales that make them a popular choice. First, they’re lightweight, easy to use and small enough to be taken anywhere. The display screen means you don’t have to memorize specific measurements as you can just look at the numbers. Plus, many models have a plug so you can use them with a USB cord, so you don’t have to worry about batteries.

 

 How Much Does an Analytical Balance Cost? 

The cost of an analytical balance can vary depending on the brand, model, and where you purchase it from. Typically, you can expect to pay anywhere from $600 to $5,000 for a good quality one. Of course, if you only need it for personal use then you could probably get away with spending less, but if you need it for business purposes then it might be worth investing in a higher quality product. Essentially you want a good quality balance. Depending on your environment and how many measurements a day that you perform will help you figure out what you want in regards to an analytical balance. 

 

How to Find the Right Balance for You

Choosing the right balance for your needs starts with understanding your specific needs, such as the weight range you need to cover and the accuracy you need. Once you know these things, you can figure out which balance is best for you. Below are a few examples to help you out. - If you’re a bakery that deals with ingredients and spices all the time, electronic and digital scales are the way to go. They’re lightweight, easy to use and fast, so you don’t have to spend as much time weighing ingredients. - If you deal with small quantities of liquids or solids, such as chemicals or pharmaceuticals, you’ll want to look at mechanical balances. They’re more accurate than electronic scales and they’re also much more affordable than digital scales. - If you deal with weights that fall in between these categories, mechanical balances are the way to go. They’re accurate and affordable, so you don’t have to worry about breaking the bank.

Closing Words

In conclusion, an analytical balance is an important tool that can be used in many different settings. They come in both mechanical and electronic varieties, with the latter being more commonly used in laboratories. The cost of these devices can range from $600 to $5,000 depending on the brand and model that you choose. When selecting an analytical balance for your needs, be sure to take into account factors such as accuracy, durability, and how frequently it will be used. By doing so, you will be sure to find the perfect product for your specific application.

At American Scale we strive to bring you informed and useful content on all things scale related. Be sure to check out our legal for trade truck scale system articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. We also have articles on scale accessories, common problems to prolong your scales lifespan, weighing applications as well as what scale indicator works best with your junction box. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' andHow Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership.

How Scales Benefit Agriculture

Industrial scales play a pivotal role in the agriculture and farming industries. They are a useful tool that can help streamline the harvesting process. Industrial scales used in farming have been proven to have a significant effect on both efficiency and profitability throughout production. Accurate measurements are essential to a profitable organization. From tracking yield to handling feed and livestock, high-volume farmers and agricultural enterprises rely on weighing solutions to ensure ultimate precision in their day-to-day weighing processes.  The advancement of technology in the scale industry has been changing the agriculture and farming process for the better. Having the ability to check livestock weights in real time as well as checking feed accuracy allows for farmers and ranchers to get ahead of any potential problems that may arise. Farming and agriculture have benefited greatly from industrial scales and the continuous push for accuracy. In this article we will take a look at how industrial scales are benefiting the agricultural industry.

The Push for Accuracy

Whether dealing with grain or corn, farmers will need measurements to be taken in high volume. Typically when you are at a feed mill, you will see several truck scales, usually in a tunnel so feed can be distributed directly and weighed at the same time. When there is not a reliable accurate weighing solution, it becomes difficult to determine the exact weight needed as well as the actual profitability of their yields. Scale manufacturers have developed great scales for farming and agriculture that are tailor made to handle the agriculture environment. The scales offer top notch accuracy  as well as greater efficiency and convenience.

INCREASED measurements

Due to the advancements in technology, livestock and other agriculture scales have drastically increased productivity as a whole. Having the ability to monitor weight in real time allows for farmers to make adjustments accordingly, thus remedying any issues before they even arise. As a result of faster calibrations and monitoring, it has increased the amount of traffic that comes through. Along with less downtime to fix the scale, which leads to reduced lost profits. As a result of  having a reliable and accurate weigh solution, the increased truck throughput is inevitable. Increased throughput means increased profits.

Versatility in motion

The amount of farm scales available from different manufacturers is substantial. You have a lot of options to choose from, and with the right scale choice, farmers can save considerable weighing time with how fast scales can record weight. Farmers greatly benefit from portable scales as well. Having the ability to move the scale to wherever you need, adds a level of versatility that was not readily available before. With the addition of onboard truck scales, they have become convenient in measuring heavier loads, thus reducing labor time due to eliminating the need to visit an external truck scale.

Simple yet detailed installs. 

When receiving a truck scale, it is usually installed on site. The length of the installation process is dependent on several factors, including foundation, size and deck style. Whether your operation calls for a grain scale, truck scale, or livestock scales, it is fairly simple to install at just about any site. Industrial scales are manufactured with high-quality material, with ease of use for the customer in mind. Scale manufacturers understand the importance of reliability and know that in the agriculture industry that reliability is essential. 

SEAMLESS INTEGRATIONS

Many farmers and ranchers have been looking for solutions that help them better manage their livestock and harvest data, to help them make changes or adjustments wherever necessary. Industrial scales have really come a long way, and have given farmers the ability to better monitor their livestock and crops. With digital integrations for load cells, indicators and accessories, the ability to monitor, record and adjust is more streamlined than before. Even with older analog scales, the transition to digital has become seamless. The accessibility farmers have to scale technicians is more prevalent than before.  

Closing words

As technology continues to advance so will society and industries. With these advancements in the scale industry continue to shine, other industries will continue to advance. The reduction of cost, down time and shrink has greatly benefited farmers as a whole. New tech is always on the horizon, and with the addition of AI among other advancements the possibilities are endless.

At American Scale we strive to bring you informed and useful content on all things scale systems related, including products from the top scale manufacturers. Be sure to check out our truck scale articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' andHow Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership. Also, take a look at our“Common Problems With Bench Scales'', to help prolong the lifespan on your scale.

How Technology Is Changing The Scale Industry

robot arms

The process of weighing and measuring goods is one of the oldest industries. While innovations in software, sensors, and other digital technologies have made the digital age more convenient than ever before, this has also led to a number of challenges for the future of scales and weighing in general. With technological advancements constantly evolving and new solutions emerging at a faster pace than ever before, it is hard to predict what challenges will arise in the near future. However, based on current trends and recent industry developments, we can expect several changes in the way weights and measurements are handled over the next few years. Here are 4 ways that weighing & measurement will change in the future.


Automated weighing and measurement

Automated systems have the potential to transform the way we handle weights and measurements. While the benefits of automation are clear, we are yet to experience the full potential of this technology. Considering the current state of automation, not all sectors will be able to fully benefit from the advantages of this. In the future, we can expect automated systems to grow in popularity. As the technology improves, we can expect the automation of more and more tasks. At the same time, we can also expect automation to bring its own set of challenges. 

In some ways you are seeing how automation has entered the scale industry. When you look at truck scales, or large weigh operations, some are adopting automated kiosks, or smart weighing for ticketing. There is also a push for contactless weighing, for when a truck can enter a weighhouse and sensors mark the arrival and distribute the product accurately. This removes the need for a person to observe, and frees them up to complete other tasks. Even with food processing plants, there are automated checkweighers that help streamline the process.

The adoption of more automated scale technology will benefit the scale owners, by allowing for their workers to tend to other duties, as well as keeping the truck drive safely inside of his truck. 

Rise of the Digital age

The rise of digitalisation is expected to continue. While digitalisation has revolutionized many sectors, it has also brought along its fair share of challenges. Things are expected to get even more challenging as the world moves further towards automation. The fact that digital assets are not always easy to transfer or exchange poses a challenge.

With a lot of truck scale companies going digital, there is a push to move away from the more antiquated ways of operating. Digital load cells and indicators with a digital screen are quickly becoming the standard. You also have ways to remotely track scale performance, allowing for the scale technician or whomever to track the data while tending to other duties. The rise of the digital era has essentially changed the way we view everything. Scale manufacturers are also adopting the digital age, by making their literature easily accessible from a computer or phone. This means if there is an issue with the scale that you need to troubleshoot, then there is most likely a guide for your specific scale online. The scale industry are just one of the many industries that have completely transformed in every way. 

weighing the benfits of Blockchains

Blockchains are in some ways still new to a lot of people, but they have been present for a little bit now. And they are being used in many industries, mainly shipping and logistics. Blockchain enables smooth and integrated communication across complex supply chains. 

In this way, it improves trust, security and speed. It can even be used to create platforms where logistics service providers offer free capacity in trucks or ships in real time.

The usage of blockchain-based solutions is expected to grow. The blockchain is more than a single technology — it is a framework that is used to build many different applications. The blockchain’s ability to automatically record and track data has made it one of the most popular technologies in the market. Several industries have started using the blockchain for their solutions. The many applications of the blockchain make it an ideal solution for a range of future challenges.

This technology is still a bit foreign to a lot of people, but is being used throughout companies like Oracle, Microsoft and IBM among others. When it comes to keeping track of inventory, shipments and payments. With blockchain support, it greatly affects the logistics industry in the way ledgers are managed, to the way shippers are paid. There are a lot of logistics companies using blockchain technology to keep track of their complex schedules, transactions and inventory. 

AI supported smart solutions will emerge

AI has come a long way in the past few years. This is expected to continue as more businesses move towards incorporating AI into their processes. AI-based smart solutions are expected to emerge over the next few years. This can be used to automate a range of processes. At the same time, it can also be used to help businesses manage their operations more efficiently.

We already have AI winning art contests and writing music and winning awards. AI is very beneficial for simplifying and streamlining many different processes. Being able to program the parameters into a computer will greatly reduce issues like human error. AI is transforming the weighing processes, such as collecting and analyzing information from the scale, truck load cells, etc. It also analyzes inventory processes, enabling companies to increase efficiency and boost revenues. In warehousing, AI is used to make demand predictions, modify orders, and reroute products in transit. Having the ability to analyze in realtime if a vehicle is overloaded, will greatly reduce fines with the state weights and measures organization. AI will definitely be used more an more as the technology advances. 

Conclusion

The future of measuring and handling goods is expected to be interesting times for the industry. With constant advancements in technology, it is not surprising to see many changes in the way we handle weights & measurements. Automated systems are expected to grow in popularity. At the same time, the usage of blockchain is expected to grow. AI-supported smart solutions are also expected to emerge. The future of measuring and handling goods looks to be very exciting.

At American Scale we strive to bring you informed and useful content on all things scale systems related, including products from the top scale manufacturers. Be sure to check out our truck scale articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' andHow Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership. Also, take a look at our“Common Problems With Bench Scales'', to help prolong the lifespan on your scale.

Tips for Improving Scale Performance.

Truck scales are ubiquitous in the freight industry. Whether it’s at a railroad, on-site weigh station or general freight terminal, truck scales are an essential tool for shippers and truckers alike. These tools allow companies to accurately weigh trucks before they are allowed to enter certain facilities. In addition to providing a means for owners and carriers to accurately weigh their vehicles, truck scales also serve as an important source of data that can be used to improve performance. That being said, not every truck scale is created equal and in this article we will be discussing tips that can maximize your truck scale performance. 


Regular Testing

Testing your truck scale regularly is a good way to keep good insight into how your scale performs. A good way to implement this is to set up a maintenance and service schedule for your truck scale. Setting up a service schedule will help you to get ahead of any potential problems that could arise during operation. Essentially a service schedule gives great insight to the overall health of your scale and keeps your scale running optimally throughout the lifespan.

In order to maximize truck scale performance, it would be recommended to test your scale at least once every two months. Considering that the general rule of thumb is to have your truck scale calibrated every quarter (3 months). This testing should be thorough and well documented. A well detailed test will have your scale technician doing a thorough visual inspection of the scale, checking for any discrepancies and any visual issues with equipment. From there they will check the accuracy by using test weights on the scale.

This process can seem a bit tedious and time consuming, but if you are running an operation that has a significant amount of measurements per day, then this may be a procedure that you will want to implement. This will also help prevent future downtime, since the scale will be serviced more frequently.  If anything, this will give you a clear picture of your scale’s performance month to month, thus allowing you to make adjustments where necessary. 

 

Maintain accurate recordkeeping

Good record keeping is essential in order to keep information on your scale organized and up to date. This will also keep a steady stream of info on your scale. You will avoid gaps of service information. When the operator records the data from their truck scale, they need to be careful to make sure that the numbers are accurate.

There are a few methods that truck scale operators can use to keep their load records accurate. For example, some scales will have an “automated” feature that automatically documents the weight. If an operator  is using one of these scales, they can still manually enter the load documentation at the same time they are entering the weight. Depending on the indicator and other accessories that are connected to the scale will determine how much data it can hold.

It is also a good idea to have a backup of all your records as well. If your scale is automated then it most likely will have a setting to record all measurements. It is suggested to also back those documents up to a usb drive, cloud (drop box, google drive) or even an external hard drive. Good recordkeeping is similar to good housekeeping. This gives you an ever growing reference for your scale as well as adding peace of mind due to knowing when each service was performed. 

 

American Scale Company techs

Involve your customers in maintenance programs

When trucking, it’s important to interact with your customers. Setting up a scale service program is a good way of building a relationship. This can be done at the gate or it can be done electronically. The point is that over time you will develop a relationship with the customers you provide maintenance for. Get into the habit of involving your customers in some of the processes to help them gain a good perspective as well as gain confidence in ownership. There are often times where there is very to litte interaction when it comes to service, but building a good relationship will help you and the scale owner get ahead of any potential problems as well as helping the owner better understand their scale.

 

Good Housekeeping

pressure washing

Weighbridge cleaning maintenance should take place as part of a daily or weekly routine depending on the type of site. The build-up of debris and water should be monitored and obstructions should be removed from beneath the scale to provide clearance between the weighbridge and the ground. Otherwise, your scale accuracy will suffer.

Pit weighbridges should be checked to make sure clearances are clean and the correct gap between the deck and pit wall are in place. ‘T’ section rubber can be used to help maintain gaps and should be replaced if worn or damaged. Regular end-middle-end tests with a loaded truck should be carried out to review the accuracy of the scale to see if there are any buildup issues. This basic cleaning and maintenance can be carried out by a site foreman or truck scale weighbridge operator. Also look into scale cleaning programs

 

Conclusion

As you can see, truck scales are a critical part of the freight industry. In order to maximize truck scale performance, it’s important to be proactive when it comes to maintaining accurate records and implementing preventative maintenance programs. Finally, remember that as a weighmaster, you also need to maintain trust with your customers. That being said, by implementing these five tips, you can ensure that you are maximizing truck scale performance.

At American Scale we strive to bring you informed and useful content on all things scale systems related, including products from the top scale manufacturers. Be sure to check out our truck scale articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' andHow Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership. Also, take a look at our“Common Problems With Bench Scales'', to help prolong the lifespan on your scale.

Metal Detector Verification Guide.

metal detector

The guide to metal detector verification


Metal Detector Verification 101

Metal detectors used in food processing are essential to keeping hazardous metal particles from mixing into our food. Ensuring a metal detector is operating properly and is properly verified will keep your metal detector operating properly for its lifespan. This article will go over the process of verifying an industrial metal detector. 

 

Calibration vs Verification

When it comes to verifying a metal detector, it is essential to understand the difference between calibration and verification. Metal detector calibration is a different process compared to calibrating a scale. When it comes to ensuring that the metal detector is able to perform its task, then it goes through a verifictaion process. Verification is the act or process of proving that the metal detector meets its sensitivity requirements. This is accomplished by challenging the detector in a repeatable manner with a certified metal sphere at a pre-described time. Most often, this procedure is executed at the same time on a daily basis. Unfortunately there is no standard to which a metal detector can be set. Granted we use metal detectors to find a specified size of metal during processing.  Setting the metal detector to pick up a specific size of metal will help locate a range surrounding a specific size. A good example of this is to change the settings to s epcific size and the magnet should be able to detect 1.5mm ferrous.  Even though a metal detector can’t be calibrated, it detector can be verified and validated. The metal detector can be tested to ensure it qualifies as meeting the standards set forth in a HACCP or other plan.

One would think that verifying a metal detector would be similar to calibrating a scale, this is not the case. With a scale, you take a standard weight, lets say 10lbs and adjust the scale so that it reads 10lbs.  You might send out a scale to a 3rd party vendor who would ensure that the device is calibrated, usually to an specifically accepted standard, and measured appropriately and consistently.

Metal Detection Standards

Unlike an industrial scale, a metal detector does not have an international standard to follow to be considered calibrated (industrial scales have NSIT). There are a lof factors that can affect detectors capabilities. This section will go over the factors that affect metal detectors.

  • Orientation effect – Happens when the diameter of a wire contaminant is less than the spherical sensitivity in the test piece.  Sensitivity is measured by the ball size because some contaminants, which are often wire, are more difficult to detect based on the direction of travel through the aperture.

  • Aperture size and position – A contaminant close to the wall of the metal detector is easier to detect. The larger the aperture, the less sensitivity. For a consistent reading, products should pass directly through the center of the aperture.

  • Packaging material – The material used to pack a product also affects sensitivity. Any metal in the packaging will affect the metal detector, reducing sensitivity and possibly creating a false metal signal.

  • Environmental conditions – Vibrations and temperature fluctuations can affect the metal detector’s sensitivity.

  • Product characteristics – Some products have certain characteristics that behave in the same way as metal when passing through the detector. For example, products with high moisture or salt content, such as meat and poultry, can often create a ‘false’ signal, making it difficult to distinguish the difference between metal and product.

  • Process speed – This is not necessarily a limiting factor for conveyorized metal detectors where product passes through at a consistent speed, but performance is hindered when inspecting product passing through vertical metal detection systems pipelines because of the variations in the speed and flow of the product.

  • Detector frequency – Metal detectors operate at different electromagnetic frequencies depending on the type of product being inspected.

understanding Verification

While all these are important considerations, these are only some of the factors involved in veritying and validating a metal detector. All things being considered, the term calibration applies, ultimately, to the relationship between the metal detector and the product. Once the proper size aperture is available and each of these factors have been settled, a metal detector is “calibrated” with clean/non-contaminated product such that the product does not cause any effect on the metal detector. In simple terms, run a clean product through your detector and it shouldn’t reject the product.  The “Product Effect” is being eliminated from the testing process.

Product effect is the magnetic and conductive properties of a product. As the product passes through the aperture, it will affect the coils used in the detection process.  Metal detectors must factor this and eliminate it or ignore it. During setup, the detector needs to “learn” what is the product effect.  The detector will discover this (along with the other factors above) and can then be set to a baseline.  This is a setting in which the product (a clean product) and it’s container (paper, cardboard or other non-magnetic housing) move through the detector without setting off a detection alarm and the associated reject device.

When it comes to an audit, many people will ask an auditor to come in and “calibrate” their detectors. An auditor can assist with that, as explained, but that’s not what’s done during an audit.  The auditors job is to verify that the metal detector can achieve the specifications (usually of a HACCP plan) that the quality control department needs it to achieve.  An auditor should be able to discuss calibration and verification.

Testing Workflow

The metal detector test follows a specific flow, which helps ensure that there aren’t any skips in procedure. Below is a list of what to expect when getting your metal detector audited.

  1. The auditor will confirm that the test samples are clearly marked with size, composition, and certificate number or provide. Whenever possible, Detector Audits will supply certified test samples for testing.

  2. Unit will be monitored/observed with a product to watch for signal changes and potential interference sources.

  3. Settings will be recorded as found at time of arrival, prior to making any changes to the unit.

  4. Test samples should travel through the approximate centerline of the aperture as this is the least sensitive area of the aperture.

    • Samples should be placed within the product when possible.

    • Testing of conveyor units should be tested on the product, preferably in the lead/center/trail position.

    • Gravity units should be tested from point of product freefall.

    • Testing of pipeline units should be tested through the center of the pipe.

  5. Test samples must activate the reject device to ensure the reject device is properly removing contaminated products from production. Verifying the reject device may include:

    • Testing with contaminant at leading and trailing edge

    • Running successive packs

    • Attempting alternate packs

  6. Testing will be performed 3 times per test sample. A successful test consists of 3 (per test sample) consecutive detects.

  7. Changes to unit settings will be made, as necessary, to achieve successful testing. All changes will be recorded. These alterations should be made by plant personnel whenever possible.

Conclusion

So if the company (customer) has already established that they need to achieve 1.5mm Ferrous, 2.0mm Non-Ferrous and 3.0mm Stainless Steel, then the auditor, using a procedure outlined above, will verify that standard.  If the product changes, the standards achievable could change, so the verification only applies to the products tested on that metal detection system. A change in the product will require that the detector be re-calibrated for that product and then the auditor can verify it meets the standards intended.  Understanding the terminology means clarifying what you do on your production line and how it’s done. And in the end analysis, that makes for a safer product in the marketplace, so know the difference between calibration and verification.

At American Scale we strive to bring you informed and useful content on all things scale systems related, including products from the top scale manufacturers. Be sure to check out our truck scale articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' andHow Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership. Also, take a look at our“Common Problems With Bench Scales'', to help prolong the lifespan on your scale.

The Guide to Load Testing

Importance of Load Testing.

Understanding the limitations of your industrial equipment is essential in knowing what you can and cannot do at your worksite. This article will go over the aspects of industrial load testing and how to properly go about getting a load test done. 

 

What is a load test?

A load test is a testing process in which the performance of industrial equipment (for example cranes) is tested under a specific expected load. It determines how the equipment behaves while being under an extremely heavy load. Essentially load testing is putting the equipment up against real world work loads. The goal of Load Testing is to check performance under a specific load, thus preventing potential overloading and also allows the operator to adjust specs wherever needed.

 

How is a load test performed? 

A load test is performed to verify that a specific crane will safely perform all of its functions while supporting a test load whose weight is at least equal to the equipment’s rated capacity. Since load tests confirm the ability of the crane to safely operate, they must be completed whenever this overhead lifting equipment is newly installed, altered, repaired, or modified before being placed into service. Existing crane systems should be load tested once every four years.

The test load used must be at least 100% of the equipment’s rated capacity unless otherwise recommended by the manufacturer. The weight itself should be certified prior to testing. Load tests should be dynamic, that is they confirm that the overhead crane and hoist function safely and properly as they move to lift and lower the test load. All results should be kept on file for the life of the equipment.

 

Workflow of a load test.

Understanding the workflow of a load test will help you get a good idea as to what to expect when you need to have a load test completed. As part of the load test process, both a pre-operational inspection and a periodic inspection should be conducted:

  • Pre-operational check: This is where a service technician will assess the equipment to identify any deficiencies or damage that may impact either the safe operation of the crane. Similar to a visual inspection when calibrating a truck scale. Key areas for evaluation include confirming that the hook and latch are not damaged and work properly. Ensure that the wire rope is not broken, or improperly wound. Check that the load chain is not worn, stretched, or twisted.

  • Periodic inspection: This inspection should be performed after the load test is complete. Whoever is performing the inspection is evaluating the equipment in great detail. It includes a comprehensive examination of structural and mechanical components. Reviewed are all girders, end trucks, foot walks, handrails, trolley frames, and cabs. Further, inspection for wear, cracks, or other damage is performed on brakes, shafts, axles, wheels, couplings, sheaves and drums, transmission components, runway structures, and below-the-hook devices. The inspector examines electrical components, indicators, gauges, connection points, the trolley and runway rail, bumpers and end stops, covers and guards, and all self-contained electric, hydraulic or gasoline powered generating units.\

Load test standards. 

When performing a load test, one simply cannot attach a random number of weights to a crane and declare that safe. There are specific standards that must be followed when performing a load test. These specifications will lay out all that is required to ensure a safe load test and a passing one as well. Because they are so critical to the safe operation of overhead cranes and hoists, there are several standards and specifications that detail load test requirements. Below is the outline of standards according to different ruling bodies:

CLOSING WORDS

At American Scale we strive to bring you informed and useful content on all things scale systems related, including products from the top scale manufacturers. Be sure to check out our truck scale articles about truck scale foundation or how much do truck scales cost. We even have a guide to warranties. To learn more about bench scales, it would be good to check out our other articles such as “Bench Scale Basics'' andHow Much Does A Bench Scale Cost?”. These articles will help with the basics of bench scale ownership. Also, take a look at our“Common Problems With Bench Scales'', to help prolong the lifespan on your scale.