The installation of an Ishida DACS-G checkweigher and metal detector in combination at Polish confectionery manufacturer ZPC Otmuchów, to help the company double production capacity for its range of jellies packed into jars.
Supplied by Ishida’s Polish agent Fenix Systems, the new checkweigher and metal detector are working in conjunction with a 14-head Ishida mid-range multihead weigher to pack the jellies into jars from 90g to 210g in size. The metal detector ensures there is no metal contamination in the product and the checkweigher works to ensure every jar is within the permitted weight range.
The checkweigher is also able to feedback to the multihead weigher information on overweight packs. This means the parameters of the multihead can be adjusted to improve accuracy of each weighing and keep over-weights as low as possible.
The feature is part of the company’s Ishida Data Capture System (IDCS), its software that captures and manages data from every pack that passes over the checkweigher. This provides real-time performance monitoring that identifies opportunities for performance improvement and enhancement throughout the line to deliver OEE.
The DACS-G-S015 model is the fifth checkweigher to be installed by ZPC Otmuchów, in adddition to the eight multihead weighers the company has in operation at its four manufacturing plants.
“All our Ishida checkweighers utilise the IDCS and are therefore interconnected, so it was important that our new Ishida checkweigher could be part of this, in addition to being well-known to our people on the shopfloor,” explained Dawid Lampka, Production Manager at ZPC Otmuchów. “The checkweighers are practically maintenance- and trouble-free. In the event of any problem, we can count on the support from Fenix Systems. Importantly, issues can usually be remotely diagnosed and solved.”
The new line incorporates one of ZPC Otmuchów’s existing multihead weighers to mirror the existing line for jellies, operating at approximately 30 jars per minute. The lines are in operation 24/7.
The sticky nature of the sugar-coated jellies makes them difficult to handle and control in an automated weighing operation. To counter this problem, the Ishida multihead weighers incorporate a special C4 coating to prevent the products from sticking to contact parts.
“The use of the C4 material has been crucial, as the solution has allowed us to significantly improve our processes,” added Dawid Lampka. “Our contact with Ishida is excellent. When we bought our first models, we received full operation and maintenance training. And as well as receiving ongoing support when needed, they are also in attendance when we have any external inspections of the equipment for weights and measures legislation.”
Established in 1946, ZPC Otmuchów is a Polish producer of sweets including chocolate candies, halva, marshmallow, hard and filled candies, gummies, bars, breakfast cereals and salty snacks. Its portfolio includes two main breads, Odra and Freeyu.
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Caitlin Gittins
Editor, International Confectionery
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