Reference · built on requestOperator by FibricProduction & maintenance

Fill Weight

Watches net contents per SKU against the label and proposes a filler setpoint change or a line stop before packages fall short.

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About

Every package leaves the filler a little over or under. Fill Weight reads the checkweigher's result stream and per-product statistics, the filler's target and fine-feed setpoints, and the item running, then compares the running mean and the low-weight reject counts against the quantity printed on the label. Checkweighers that follow OPC UA for Weighing Technology expose these as NominalWeight, LowerToleranceLimit1 and LowerToleranceLimit2, TotalPackagesRejected, and GiveAway. Older scales expose the same numbers as Modbus registers you map.

When the mean drifts toward the label, or rejects for low weight climb, it proposes a setpoint change inside the bounds you declared, or a line stop. A person approves. It never writes to the filler on its own.

This is a reference listing. It documents what Fibric would read from Fill Weight and what it could propose, based on the vendor's published interfaces. Fibric builds it under a managed deployment when you request it; selecting it here installs nothing.

Inputs

  • Per-package weights and accept or reject results from the checkweigher, as OPC UA nodes or as Modbus registers on the scale controller
  • Per-product statistics from scales that follow OPC 40200: TotalPackagesAccepted, TotalPackagesRejected, PackagesRejectedByLowerToleranceLimit1 and 2, GiveAway
  • Filler setpoints on the PLC: TargetWeight, FineFeedWeight, and InFlightWeight per product, or the holding registers your register map names
  • The product selected on the scale, from CurrentProducts under ProductionPreset, so a preset left over from the last SKU is caught
  • The item running on the line from your MES or ERP: the item number and gtin from Business Central items, or a NetSuite saved search
  • NominalWeight per product from the checkweigher, or the declared net quantity per SKU from a list you provide
  • unitCost from the ERP item record, so give-away is shown in money as well as in units of mass

Proposed actions

  • Target capability: propose a TargetWeight change on the filler, inside the bounds declared for that register or node, for the line lead to approve
  • Target capability: propose a line stop, or a hold on the running job, when the mean falls toward the nominal or low-weight rejects climb
  • Target capability: propose a product check when the item on the job and the product selected on the checkweigher disagree
  • Target capability: propose a hold on the packages produced since the last in-tolerance sample, with the count and the time window shown
  • Target capability: propose a note to the quality lead with the shift's give-away, in units of mass and at unit cost

Proposed actions are target capabilities. Every action runs propose-first and needs a validated deployment and the appropriate permissions.

What you can build

  • Trim give-away on a bottling line

    GiveAway rises over OPC UA while every package passes. The operator proposes a lower TargetWeight on the filler through the PLC Command Bridge, inside the declared bounds, with the running mean and the nominal shown side by side.

    With OPC UA, PLC Command Bridge

  • Stop before the short packages ship

    PackagesRejectedByLowerToleranceLimit1 climbs on one lane. The operator proposes a line stop and a hold on the Plex job, naming the lane and the packages counted since the last clean sample.

    With OPC UA, Plex

  • Catch the preset from the last SKU

    Business Central shows the line switched items at the changeover. CurrentProducts on the checkweigher still names the old product. The operator proposes a product check before the next case is palletised.

    With Microsoft Dynamics 365 Business Central, OPC UA

  • Read an older filler over Modbus

    A filler with no OPC UA server exposes its setpoint and last net weight as holding registers. With your register map and scaling, the operator reads them on the polling schedule and prices give-away from item cost in a NetSuite saved search.

    With Modbus TCP, NetSuite

Requirements

  • A checkweigher reachable over OPC UA or Modbus TCP, with a node list or a register map for weights, results, and statistics
  • The filler's setpoint registers or nodes declared as writable targets with bounds in the PLC Command Bridge
  • The declared net quantity per SKU: NominalWeight on the scale, an ERP item list, or a spreadsheet you maintain
  • An MES or ERP connector that says which item runs on which line, or a job list you provide
Authentication
Reads scale and filler values through the credentials your OPC UA, Modbus TCP, and controller connectors hold, and writes a setpoint only through the PLC Command Bridge after approval.

Limits

  • It sees only packages the checkweigher weighed. Product that bypasses the scale, or is pulled before it, is invisible.
  • It is not a legal metrology check. NIST Handbook 133 lot sampling and its tables of Maximum Allowable Variation still govern what ships.
  • Setpoint proposals reach only registers or nodes declared writable with bounds. It never changes the checkweigher's own tolerance limits.
  • Modbus TCP carries no product names or units. Without a register map with scaling, weights cannot be read at all.

Access and pricing

Reference listing. Fibric builds the operator under a managed deployment when you request it. Your quote covers the build, capabilities, usage, and support.

Request Fill Weight ↗

Questions and answers

What does a person approve?
Each setpoint change, line stop, hold, product check, and note. The proposal shows the running mean, the nominal, the reject counts, the current setpoint, and the value proposed. Approve it, change the value, or dismiss it. Nothing is written until then.
What record is left?
A receipt per proposal: the samples and statistics read, the SKU and the product preset, the setpoint before and after, who approved, and when. An approved change is written once and read back from the controller. A declined proposal is kept with the reason.
Will it change the filler or stop the line on its own?
No. It reads and proposes. A setpoint write goes through the PLC Command Bridge after approval, and only to a target you declared with bounds. Stops and holds go to a person or to your MES. It never edits the checkweigher's tolerance limits or the label's declared quantity.
Ask about Fill Weight

Ask about the capabilities and requirements in this listing.

For project-specific requirements, contact Fibric.

This operator is developed, published, and supported by Fibric. Third-party names and logos identify the systems an integration connects to; they are the property of their respective owners, who are not affiliated with Fibric and do not sponsor or endorse this listing. Trademark policy