Case Study: How PATA Achieved Compliance with Checkweighing and Metal Detection

PATA operates on a 24-hour production schedule from Monday to Friday, meaning that production equipment needs to be capable of consistent operation for enormous stretches of time. Any given production line will see up to six different varieties of potato chips run on it over the week, so equipment needs to be able to switch between product profiles easily. A push to add end-of-line automation in 2008 led to the company purchasing dynamic checkweighers from METTLER TOLEDO – which have gone from an initial order of three units to the most recent order of ten additional systems. PATA is very satisfied with the weighing accuracy delivered by the dynamic checkweighers as it allows them to optimize their filling processes. ''We greatly benefit from the solution in two ways: first, in terms of percentage savings in filling quantity – because weighing 100% of the products enables us to be more precise and apply tighter tolerances – and second, in terms of the minimized number of unsatisfactory lots that need to be recalled, reopened or repackaged," says Massimo Piona, PATA Production Manager.

The latest Profile metal detectors installed have Reduced Test (RT) Mode included as standard. With RT Mode, the metal detector operates at a higher specification than what is required, and notifies the operator if performance drops, providing an advance warning before the metal detector goes out of specification. When RT Mode is active, it allows for a significant reduction in the frequency of routine performance monitoring tests (within the quarantine period), which has delivered a significant improvement on production line uptime. PATA also benefits from detecting smaller metal contaminants, enhancing brand protection and minimizing the risk of costly product recalls.

Service Routines Deliver Smooth Operation

In addition to their metal detection systems and checkweighers, PATA also has an annual maintenance contract with METTLER TOLEDO to make sure all their equipment continues to function properly. METTLER TOLEDO service technicians check the performance and test the equipment to make sure it is functioning at peak capability. On-site spare parts kits for commonly worn components enable quick replacements, minimizing unexpected downtime. Most importantly, PATA makes sure that their employees receive training on proper equipment use. New hires are paired with experienced workers through a structured program lasting 15 days to three months, depending on experience, to share knowledge and support their development. This training, combined with user-friendly interfaces of METTLER TOLEDO Product Inspection equipment, reduces operator errors. 

A Productive Partnership

METTLER TOLEDO and PATA have been working together for decades, strengthening their partnership over time. As METTLER TOLEDO advances its inspection technology, PATA continues to reap the benefits as they add more product inspection equipment to their production process. This enables PATA to stay compliant with the demands of their industry and their customers, while minimizing production delays and product waste.