Key Highlights:
- Greenyard integrates Mettler-Toledo’s C33 PlusLine checkweighers.
- Overfill reduced from 40 grams to 10 grams per one-kilogram bag.
- Efficiency improved and manual adjustments largely removed.
- Savings achieved through better weight control and waste reduction.
Greenyard Frozen Belgium has improved packaging accuracy and reduced product waste at its Westrozebeke plant by using Mettler-Toledo’s advanced checkweighing technology. The move aims to tackle long-standing overfilling issues and cut unnecessary product losses in high-speed packaging lines.
The company, which produces and packages millions of frozen fruits and vegetables every year, had faced ongoing challenges with excess fill levels. To avoid underweight packages, Greenyard used to add around 40 extra grams to each one-kilogram bag. While this ensured compliance, it also led to large amounts of product being given away for free over time.
Manual adjustments failed to deliver consistent results. To solve this, Greenyard turned to Mettler-Toledo’s C33 PlusLine checkweigher, a system equipped with automatic fill level correction. The device continuously tracks each bag’s weight and adjusts filling in real time, keeping every package within the correct limit.
After full implementation, the company saw major improvement. Overfill dropped from 40 grams to just 10 grams per bag while maintaining accuracy and compliance. Technical Manager Dominiek Vierstraete said the results were better than expected. “We tested the smart fill feature on one line and the outcome convinced us to install it across all lines,” he said.
Each packaging line required separate calibration for different vegetables, such as peas and cauliflower. Mettler-Toledo’s team supported installation, setup and staff training. Once in place, the system worked automatically, reducing the need for manual checks.
Efficiency gains were clear. On one packaging line, overweight rates fell from 0.69% to 0.14% and from 0.30% to 0.11% on another. Though the numbers seem small, the savings add up quickly across Greenyard’s large production volume. “This saves product, prevents waste and makes the process smoother,” Vierstraete explained.
The company also benefited from less operator intervention, faster performance and more reliable data. “It’s an investment that pays back quickly,” Vierstraete added.
Mettler-Toledo representatives said such improvements are common when manufacturers use smart weighing systems. “Every gram matters when margins are tight. Many companies recover the investment within months,” said Mari Bögels, Account Manager at Mettler-Toledo Product Inspection.
Field service technician Janus Dumelie noted that collaboration was key to success. “We don’t just install the equipment. We work closely with customers to make sure they get the best performance every day,” he said.
Greenyard’s use of intelligent checkweighing shows how automation can improve precision and reduce waste in large-scale food processing. With tighter control over fill levels, the company cuts costs, saves raw material and strengthens its focus on efficiency and sustainability.
Source: Food Manufacturing
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