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Checkweighers for 100% Pre-packaged Goods Control

RADWAG checkweighers for 100% control weigh every single product moving along the production line and automatically reject items whose mass is outside the set limits. They are used for pre-packaged goods control (PGC) in accordance with the regulations on pre-packaged goods, as well as for checking products against the manufacturer's own criteria. The range covers devices for loads from 300 g to 60 kg, with a readability from 0.1 g and a throughput of up to 500 packages per minute – from precise DWM checkweighers and multi-track DWM H2 scales, through DWT/RC scales for heavy loads, to hermetic IP 69K versions, the DWM/HPW with a metal detector and DWR rotational scales for bottles and aerosols. All devices are designed and manufactured by RADWAG in Poland.

What is 100% control?

In 100% control, every package is weighed – not just a sample. A checkweigher is installed in the line after the filling or packing machine: the product is weighed on a conveyor in motion, the result is compared with the set thresholds, and an underweight or overweight package is removed by a rejecter (air jet, pusher, swing conveyor). Unlike statistical PGC control, in which an operator checks samples on a static scale, 100% control guarantees that no non-compliant product reaches the customer, and the data from each weighing goes into reports.

RADWAG checkweighers for 100% control

Types of checkweighers for 100% control

• Control scales – DWM HY10 Basic (compact, up to 150 pcs/min), DWM (up to 500 pcs/min, MID certificate, pharmaceutical version) and DWM H2 multi-track scales that collect products directly from multi-track packaging machines. For heavy loads and cartons up to 60 kg – DWT/RC.
• Control scales with contamination detection – the DWM/HPW combines weighing with a metal detector in one machine and rejects defective and contaminated products into separate bins. More metal detection solutions can be found in the metal detectors category.
• Hermetic control scales – DWM HPX (up to 7.5 kg) and DWT/RC/HYF (up to 60 kg) with IP 69K protection, designed according to hygienic design principles for meat, fish and dairy processing, where the line is washed with high-pressure water.
• Rotational control scales – DWR 1500 for cylindrical containers: aerosols, sprays, glass and plastic bottles. The device has no conveyor of its own – it is mounted over the existing line.

Software, data and integration with the line

The checkweighers are controlled by an industrial computer with a touchscreen (Windows 11 IoT or Linux) and an SQL database of products, operators, weighings and reports. Real-time statistics, a line performance meter and automatically generated reports exported to PDF make it easy to document production. The E2R system synchronises data from several checkweighers with a central database.

As standard, the devices have RS232, USB, Ethernet and digital inputs/outputs; PROFIBUS, PROFINET, EtherNet/IP and Modbus are available as options. They can control a filler in a feedback loop (correcting the dose based on the weighing result), work with barcode scanners, printers and labellers, and signal states with stack lights. The checkweighers are verified as automatic catchweighing instruments of class XIII(1) / Y(a) – the OIML class required for pre-packaged goods control.

Applications of 100% control

• food industry – checking the mass of packaged foods, sweets, frozen products and ready meals,
• meat, fish and dairy processing – hermetic IP 69K checkweighers,
• pharmaceutical industry – weighing medicines, blisters and syrups in compliance with GMP and 21 CFR Part 11,
• cosmetics and chemical industries – control of bottles, tubes and aerosols (DWR),
• distilling and brewing – checking the filling of bottles and collective packaging,
• logistics and shipping – verification of cartons and collective packages up to 60 kg (DWT/RC).

How to choose a checkweigher for 100% control?

• Product mass – up to 7.5 kg: DWM, DWM H2, DWM/HPW or DWM HPX; up to 60 kg: DWT/RC or DWT/RC/HYF; cylindrical containers up to 6 kg: DWR.
• Line speed – up to 500 pcs/min for DWM series checkweighers (per track in DWM H2), up to 150 pcs/min for DWM HY10 Basic, up to 100 pcs/min for DWT/RC.
• Working environment – IP 55/65 for typical production halls, IP 69K for high-pressure washing (DWM HPX, DWT/RC/HYF).
• Contamination detection – if you also need to detect metal, choose the DWM/HPW.
• Industry requirements – for pharmaceuticals: Audit Trail, 21 CFR Part 11 and IQ/OQ/PQ validation (DWM, DWM HPX, DWM/HPW).
• Rejection method – air jet, pusher, swing conveyor or separate bins for underweight and overweight products – configured to suit the product.

FAQ – checkweighers for 100% control

What is the difference between 100% control and statistical control of pre-packaged goods?

In statistical control, samples are taken from a batch and weighed on a static scale, and the result is assessed using statistical methods. In 100% control, a checkweigher in the line weighs every package and automatically rejects those outside the limits, so no non-compliant product leaves the plant.

How many products per minute can a checkweigher weigh?

DWM, DWM/HPW and DWM HPX checkweighers weigh up to 500 packages per minute, and the multi-track DWM H2 up to 500 per minute on each track. The DWM HY10 Basic handles up to 150 pcs/min, the DWT/RC up to 100 pcs/min, the DWR up to 80 pcs/min and the DWT/RC/HYF up to 50 pcs/min.

Can a checkweigher detect metal contaminants?

Yes. The DWM/HPW checkweigher has an integrated metal detector. It rejects products with incorrect mass and products contaminated with metal into separate bins, which helps meet HACCP requirements.

Which checkweigher is suitable for washdown areas?

The DWM HPX (up to 7.5 kg) and DWT/RC/HYF (up to 60 kg) checkweighers. They have IP 69K protection, a stainless steel structure without places where dirt can accumulate, and belts that can be removed without tools or washed without disassembly.

Can the checkweigher correct the filling machine?

Yes. RADWAG checkweighers can work with a filler in a feedback loop: based on the average mass of weighed packages, they send correction signals so that the filler doses closer to the nominal value.

Are RADWAG checkweighers suitable for the pharmaceutical industry?

Yes. DWM series checkweighers offer an extended access control module, an Audit Trail recording all changes, compliance with GMP and 21 CFR Part 11, and a qualification package for IQ, OQ and PQ validation.

Planning 100% control on your production line? Contact our specialists – we will help you choose the checkweigher, conveyor and rejection system, and provide technical support.