Published on July 6, 2026 | Industrial End-of-Line Weighing Solutions
For fast-moving consumer goods manufacturers with end-of-line carton packaging, missing pieces and underweight cartons have long been a persistent quality pain point that directly leads to retailer penalties, brand reputation damage and reverse logistics costs. For heavy cartons and barrel packages, manual weighing not only has high missed detection rate, but also brings great labor intensity and low operation efficiency. Recently, Shanghai Fanchi-tech Machinery Co., Ltd. deployed a customized roller conveyor inline checkweigher solution for a leading bottled daily chemical manufacturer in Vietnam, helping the client achieve 100% full weight inspection of finished cartons on the automatic packaging line, and completely solve the problem of missing product outflow.
Client Challenges
The client is a well-known daily chemical enterprise in Southeast Asia, focusing on the production of bottled laundry detergent, dish soap and personal care products. Its end-of-line packaging line covers 5kg barreled products and 500ml bottled products (12 bottles per carton), with a designed capacity of 55 cartons per minute and 20-hour daily operation. Before adopting Fanchi-tech's solution, the production line faced four core pain points:
- High missed detection rate of missing pieces: Manual sampling only covered about 10% of finished cartons. Missing 1-2 bottles in a carton occurred from time to time, resulting in frequent retailer complaints and penalty deductions, with annual direct losses exceeding 90,000 USD.
- Low efficiency and high labor intensity: Each carton weighs 6-15kg. Workers need to carry and weigh repeatedly, with high labor intensity and high employee turnover. The manual weighing speed can only reach 20 cartons per minute, which has become the bottleneck of the whole packaging line.
- Lack of data traceability: Paper-based weighing records cannot be traced back to the specific filling and cartoning station, making it impossible to locate the root cause of weight deviation and optimize the front-end process in a targeted manner.
- Poor line compatibility: The original production line adopts roller conveyor structure, and ordinary belt checkweighers cannot be seamlessly docked, requiring large-scale line transformation and long downtime.
After on-site survey of the client's workshop layout, product specifications and existing line structure, Fanchi-tech configured the FC-CW Series heavy-duty roller inline checkweigher for the back end of the client's automatic cartoning machine. The equipment adopts a combined structure of front roller feeding section + belt weighing section, which can be seamlessly connected with the client's original roller packaging line, and the installation and commissioning can be completed within one day without affecting normal production.
Core configurations and scenario advantages corresponding to the equipment:
- Roller + belt combined conveying structure: The feeding section adopts all-stainless steel power roller conveyor, which matches the height and width of the client's original roller line, ensuring smooth transition of heavy cartons without jamming; the high-precision weighing section adopts food-grade blue belt, matched with imported high-precision load cells, to ensure stable weighing accuracy under long-term heavy load.
- Heavy-duty industrial stainless steel frame: The whole machine is made of 304 brushed stainless steel with thickened square tube frame, which has strong structural rigidity and strong bearing capacity, adapting to 5-50kg carton, barrel and bag products, and meeting the requirements of long-term continuous production in industrial workshops.
- Intelligent control and status warning system: The vertical control cabinet is equipped with a 7-inch color touch screen, which supports storage of up to 100 product formulas, one-click parameter switching, and real-time display of weighing data, pass rate and rejection statistics. The tri-color warning light on the top gives real-time feedback of equipment running status, and the emergency stop button is configured to meet industrial safety production standards.
- Stable carton rejection mechanism: Equipped with push-rod type rejection device, it can stably remove unqualified cartons with missing pieces or overweight, without carton dumping or package damage, and does not interrupt the continuous operation of the production line.
- Shock-absorbing adjustable support feet: The height-adjustable anti-slip rubber support feet can adapt to different workshop ground conditions, effectively reduce the impact of ground vibration on weighing accuracy, and ensure long-term stable operation of the equipment.
- Production data traceability function: The system automatically stores weighing data and supports Excel export, which can be docked with the client's MES production management system to help the quality department locate the deviation of filling and cartoning stations and optimize front-end process parameters.
After 2 months of stable operation, the client's 3 packaging lines have achieved comprehensive improvements in quality control, efficiency and cost:
- Zero outflow of missing-piece defects: 100% full inspection of all finished cartons is realized, and all underweight cartons with missing bottles are accurately rejected. The retailer complaint rate dropped by 98%, and the annual penalty and reverse logistics cost was reduced by about 85,000 USD.
- 60% increase in line efficiency: The equipment runs stably at a speed of 60 cartons per minute, which is fully synchronized with the cartoning line speed, completely eliminating the weighing bottleneck and increasing the overall daily output of the packaging line.
- 70% reduction in labor cost: Each line is reduced from 6 weighing operators to 1 patrol inspector, which greatly reduces the labor intensity of workers and the cost of employment and training, and effectively solves the problem of high employee turnover in heavy physical work positions.
- Reduced raw material waste: Through accurate weight data analysis, the client optimized the filling parameters of the front-end filling machine, reduced the average overfilling amount, and saved about 112,000 USD in raw material costs annually.
- Upgraded quality management system: Traceable weighing data meets the requirements of ISO9001 and GMP quality management systems, helping the client successfully pass the supplier audit of international chain supermarkets and expand more high-end customer channels.
Why Choose Fanchi-tech Roller Conveyor Checkweighers
The roller-type inline checkweigher is a classic heavy-duty weighing model of Fanchi-tech, which is widely used in end-of-line inspection scenarios in food, daily chemical, pharmaceutical, hardware and other industries.
- Strong line compatibility: The roller feeding structure can be seamlessly docked with various roller packaging lines and palletizing lines, avoiding large-scale line transformation and shortening the installation and commissioning cycle.
- Stable heavy-load performance: Thickened stainless steel frame with high-strength conveying structure, no precision drift under long-term heavy-load operation, and long service life.
- High degree of customization: Conveying width, weighing range, rejection method and communication interface can be fully customized according to customer product specifications and production line conditions.
- Easy maintenance: Modular design of rollers and belts, which can be quickly disassembled for cleaning and replacement, reducing equipment downtime and maintenance costs.
Shanghai Fanchi-tech Machinery Co., Ltd. focuses on the R&D and manufacturing of industrial inspection equipment, providing professional solutions including checkweighers, metal detectors and X-ray inspection systems for global manufacturing customers. With rich on-site customization experience and complete product matrix, the company serves customers in dozens of countries and regions, and is committed to helping clients improve production quality and reduce operational costs.
For more details about our roller conveyor checkweigher and customized end-of-line inspection solutions, welcome to contact our team:
- Contact: Kerry
- Email: kerry@fanchitech.net
- Mobile / WhatsApp: +86 13917555254
- Official Website: www.fanchitech.net
- YouTube Channel: https://youtube.com/@fanchitech3323?si=gyh-f9JCbjkJ3tEu
Post time: Jul-06-2026