Multihead Weigher Packaging Machines vs Traditional Manual Weighing and Packaging: A Comprehensive Comparison

    In the ever - evolving world of packaging, businesses are constantly seeking ways to optimize their processes. The choice between using a Multihead Weigher (also known as multi head packing machine) and traditional manual weighing and packaging methods can have a significant impact on various aspects of production, from efficiency to cost - effectiveness. This blog post will objectively analyze the advantages and disadvantages of both approaches, with a focus on the capabilities of machines like the 14 head multihead weigher.​

1. Weighing Principle​

A. Traditional Manual Weighing​

    In traditional manual weighing, operators use scales, such as manual balances or basic digital scales, to measure the product quantity. For example, in a small - scale confectionery store, an employee might place candies on a scale, adding or removing them one by one until the desired weight is reached. This process is highly reliant on the operator's attention and skill. The weighing principle is straightforward but lacks the sophistication of modern automated systems. Since it is a step - by - step addition or subtraction process, it can be time - consuming, especially when dealing with a large number of packages.​

B. Multihead Weigher​

    Multihead weighers, on the other hand, operate on a more complex and efficient principle. These machines, like the 14 head multihead weigher, consist of multiple weighing heads, typically ranging from 8 to 32. Each head has its own load cell for independent weighing. The product is first distributed into the weighing heads from a hopper. The machine's computer then uses the principle of permutation and combination to analyze the weight data from each head. It selects the optimal combination of heads that will result in a total weight closest to the target value. For instance, if the target weight for a package of nuts is 500g, the computer in the multihead weigher will calculate which combination of the 14 heads, each holding a certain amount of nuts, will sum up to the closest value to 500g. This automated and intelligent weighing process is much faster and more accurate compared to manual weighing.

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2.Speed and Efficiency​

A. Traditional Manual Weighing​

    Manual weighing and packaging are notoriously slow. Human operators have a physical limit to how quickly they can pick up, weigh, and package products. For example, in a small - scale bakery packaging cookies, an experienced worker might be able to weigh and package around 20 - 30 packages per minute. Fatigue also plays a significant role. As the workday progresses, the operator's speed and accuracy are likely to decline. Additionally, manual processes often involve more steps, such as manually filling bags after weighing, which further slows down the overall packaging speed.​

B. Multihead Weigher​

    Multihead weighers are designed for high - speed operation. A 14 head multihead weigher, for example, can achieve speeds of 100 - 120 packages per minute or even higher, depending on the product and the machine's settings. The automated weighing and discharging process allows for a continuous flow of packaging. These machines can be integrated with various types of packaging machines, such as vertical form - fill - seal machines or horizontal flow - wrap machines, creating a seamless and high - speed packaging line. This high - speed operation significantly increases production output, allowing businesses to meet large - scale market demands more effectively.​

3. Accuracy​

A. Traditional Manual Weighing​

    Manual weighing is highly susceptible to errors. The accuracy depends on the operator's experience, concentration, and the precision of the scale being used. Even with a high - quality scale, human error in adding or removing product can lead to significant weight variations. For example, in a deli where employees are manually weighing sliced meats, the weight of each package can vary by several grams. This not only affects the consistency of the product but can also lead to customer dissatisfaction if they feel they are not getting the correct amount.​

B. Multihead Weigher​

    Multihead weighers are renowned for their high accuracy. The load cells in each weighing head are extremely sensitive and can provide highly precise weight measurements. The computer - controlled combination selection process further enhances accuracy. Most multihead weighers can achieve an accuracy of within ±1g or even better, depending on the model and the product being weighed. This level of accuracy ensures that each package contains the exact amount of product, which is crucial for maintaining product quality and customer satisfaction. For products sold by weight, such as coffee beans or spices, accurate weighing is essential for both the consumer's perception of value and the manufacturer's cost control.​

4.Labor and Cost​

A. Traditional Manual Weighing​

    Manual weighing and packaging require a significant amount of labor. Multiple employees are needed to handle the weighing, filling, and sealing processes. In a medium - sized food packaging facility using manual methods, dozens of workers might be required to meet production targets. Labor costs can quickly add up, including wages, benefits, and training. Additionally, the slow speed of manual processes means that more time is spent on production, increasing the overall cost per unit. There is also a higher risk of product waste due to inaccurate weighing, further increasing costs.​

B. Multihead Weigher​

    While the initial investment in a multihead weigher can be significant, it offers long - term cost savings. These machines require only a few operators to monitor and maintain, reducing labor costs substantially. For example, a production line with a 14 head multihead weigher and an integrated Packaging machine might only need 2 - 3 operators, compared to the dozens needed for manual processes. The high - speed and accurate operation of the multihead weigher also reduce product waste, as each package is filled with the correct amount of product. Over time, the savings in labor and product waste can offset the initial investment in the machine.​

5.Flexibility​

A. Traditional Manual Weighing​

    Traditional manual weighing is relatively flexible in some aspects. It can easily handle small - batch production and products with irregular shapes or sizes. For example, in a handicraft store packaging unique items, manual weighing allows for the adaptation to different product characteristics. Operators can make on - the - spot adjustments based on the product's appearance or feel. However, this flexibility comes at the cost of speed and accuracy, and it may not be practical for large - scale production.​

B. Multihead Weigher​

    Multihead weighers are also quite flexible, despite being automated. They can be adjusted to handle a wide range of products, from small granules like salt to larger items like nuts or dried fruits. The machine's settings can be easily modified to change the target weight, and different types of packaging materials can be used in conjunction with the multihead weigher. However, changing the product type may require some setup time to adjust the feeding mechanisms and the weighing parameters. While it is not as immediately adaptable as manual weighing for very small - scale or highly irregular products, it offers a good balance of flexibility for most medium - to - large - scale production needs.

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6.Hygiene and Quality Control​

A. Traditional Manual Weighing​

    In manual weighing and packaging, there is a higher risk of product contamination. Operators' hands are in direct contact with the product during the weighing and filling process, which can introduce bacteria or other contaminants. Additionally, the open nature of manual weighing stations makes it easier for dust and other particles to settle on the product. Quality control can also be more challenging as it relies on the operator's consistency in weighing and packaging.​

B. Multihead Weigher​

    Multihead weighers offer a more hygienic packaging solution. The product is handled mostly within the machine, reducing the risk of human - to - product contact. The closed - loop control system also ensures consistent weighing and packaging, which is beneficial for quality control. Many multihead weighers are designed with easy - to - clean surfaces, making it simple to maintain a high level of hygiene in the production environment. This is particularly important in industries such as food and pharmaceuticals, where strict hygiene standards must be met.​

7.Conclusion​

    In summary, multihead weigher packaging machines, such as the 14 head multihead weigher, offer numerous advantages over traditional manual weighing and packaging methods. They provide higher speed, greater accuracy, lower labor costs, and better hygiene control. However, traditional manual weighing still has its place, especially in small - scale operations or when dealing with highly irregular products. Businesses need to carefully consider their production requirements, budget, and product characteristics when choosing between these two packaging methods. For large - scale production with a focus on efficiency, accuracy, and cost - effectiveness, multihead weighers are often the superior choice.​