Real-time weight control critical in balancing opposing objectives
Striking the optimal balance between the push and pull of meeting guaranteed minimums while avoiding overfill and overweight conditions is not an easy task.
A bottling business fills 250 ml containers at an average line speed of 1000 per minute. In order to ensure compliance with regulations and consumer expectations, it sets the upward overfill limit at .25%. This equates to an average giveaway amount of a little more than .5 ml per container.
The company must then determine whether the .5 ml overfill can be reduced, and what the resulting cost saving should be. Given their three‐shift, seven‐day production schedule, the company estimates that if it could recover the total overfill amount it would be able to fill more than 21,000 additional containers per week, or more than 85,000 containers per month. At an average cost of $0.35 per container, the savings, or unrealized revenue, approaches $30,000 per month.
It becomes easy to see why recovery of even a small percentage of this overfill is in the company’s best interest. Case study covers three industry examples and the measurable benefits: significant reduction in running limits, closer relation to label weights, compliance with FDA regulations, reduction in cost savings associated with overfill and more.
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