METTLER TOLEDO XG 300/6 Automatic Weight Sorting System

Overview

The METTLER TOLEDO XG 300/6 Automatic Weight Sorting System is a modular, stand-alone in-line sorting solution engineered for precision weight-based classification in regulated food, pharmaceutical, and consumer goods manufacturing environments. Unlike integrated weigh-sort systems, the XG 300/6 operates as a dedicated downstream module—designed specifically to interface via RS232 with existing METTLER TOLEDO Garvens checkweighers. This architecture eliminates the need for full-scale replacement of legacy checkweighing infrastructure, enabling cost-effective modernization of production lines while preserving prior capital investment. The system employs a deterministic mechanical sorting principle: products are conveyed at controlled velocity across a high-stability weighing platform; upon confirmation of stable weight acquisition, synchronized servo-controlled swing gates direct each item into one of up to twelve discrete weight zones based on pre-configured tolerance bands. Its open-frame construction, minimal horizontal surfaces, and seamless material transitions support rapid wet cleaning cycles compliant with HACCP, FDA 21 CFR Part 11 (when paired with validated software), and EU Hygiene Directive 2006/42/EC.

Key Features

• IP65-rated enclosure with stainless steel (AISI 304) structural frame and food-grade polyoxymethylene (POM) conveyor belt—certified for repeated exposure to washdown conditions in Zone 2 hygiene environments.
• Modular expandability: standard 6-zone configuration supports immediate deployment; optional X-Door expansion module adds six additional discharge chutes without requiring electrical rewiring or PLC reprogramming—installation completed in under 90 minutes.
• High-reproducibility mechanical actuation: dual-level swing gates operate with sub-20 ms timing resolution, minimizing product impact energy and ensuring low-damage handling of fragile items including baked goods, confectionery, and blister-packed pharmaceuticals.
• Compact footprint (W × D × H ≈ 1,200 × 850 × 1,100 mm) enables drop-in integration adjacent to existing Garvens checkweighers—no line rerouting or civil works required.
• Pre-commissioned delivery: fully assembled, factory-tested, and calibrated; includes embedded firmware v3.2+ supporting automatic zero-tracking compensation and real-time weight drift diagnostics.

Sample Compatibility & Compliance

The XG 300/6 accommodates products ranging from 5 g to 300 g with maximum dimensions of 250 mm (L) × 120 mm (W) × 100 mm (H). Its POM conveyor surface exhibits low coefficient of friction (μ ≈ 0.25) and non-porous surface topology, preventing microbial entrapment during CIP/SIP protocols. All wetted components comply with FDA 21 CFR §177.2475 (POM) and EC 1935/2004 food contact material regulations. The system meets IEC 60529 (IP65), ISO 14159 (safety of machinery—hygiene requirements), and EN 1672-2:2013+A1:2018 (food processing machinery—basic concepts—hygiene design). When operated with METTLER TOLEDO’s certified WeighSort Suite software, audit trails, electronic signatures, and data integrity controls satisfy ALCOA+ principles for GMP-regulated facilities.

Software & Data Management

The embedded touchscreen HMI runs WeighSort Control Firmware v3.2, supporting 12 languages (including English, German, Spanish, Mandarin, and Japanese) with intuitive zone configuration wizards and real-time statistical process monitoring (SPC). Weight data is timestamped and exported via USB or Ethernet (Modbus TCP) in CSV or XML format. Optional WeighSort DataHub license enables centralized fleet management across multiple XG units, automated report generation (per ISO 2859-1 AQL sampling plans), and integration with MES platforms such as Siemens Opcenter Execution or Rockwell FactoryTalk. All firmware updates undergo cryptographic signature verification to ensure supply chain integrity per NIST SP 800-193 guidelines.

Applications

• Food production: portion control of frozen meals, snack packs, and bakery items; rejection of underweight/overweight packages prior to metal detection or x-ray inspection.
• Pharmaceutical packaging: sorting of primary containers (vials, syringes, blister cards) by gross weight to verify fill volume consistency and detect missing components.
• Consumer electronics: classification of small assemblies (e.g., power adapters, USB cables) by weight to confirm inclusion of all accessories before final boxing.
• Chemical manufacturing: segregation of reagent kits into dosage-specific batches based on net weight tolerances defined in ASTM D4788-22 (standard practice for weight-based quality control).

FAQ

Is the XG 300/6 compatible with non-METTLER TOLEDO checkweighers?
No—the RS232 protocol implementation is proprietary to METTLER TOLEDO Garvens-series checkweighers. Integration with third-party weighers requires custom middleware development and validation.
What is the minimum weight increment the system can resolve for sorting decisions?
Sorting resolution is determined by the upstream Garvens checkweigher’s readability (e.g., 0.1 g or 1 g); the XG 300/6 itself imposes no additional quantization error.
Can the system be validated for use in regulated pharmaceutical environments?
Yes—IQ/OQ documentation templates are provided with purchase; PQ execution requires site-specific challenge testing using NIST-traceable test weights and documented SOPs aligned with Annex 15 of the EU GMP Guide.
Does the expansion module require recalibration after installation?
No—mechanical alignment is fixed at factory; only zone parameter mapping in firmware requires updating via HMI wizard.
What maintenance intervals are recommended for the swing gate actuators?
Servo motors and pivot bearings are rated for 10 million cycles; preventive maintenance (lubrication and torque verification) is scheduled every 6 months or 500 operating hours, whichever occurs first.