SysTec Weighing Solutions for Poultry Processing Lines at Noble Foods

Prior to the project, the production environment at Noble Foods relied partly on limited data from mechanized poultry processing lines and partly on manual documentation processes. While load cells were already installed in certain areas, the captured information was neither fully accurate nor easily accessible for further processing. In other areas, especially for pallet box weighing, operators recorded weights manually. This approach not only consumed time but also reduced transparency and increased the risk of errors.

The lack of centralized data visibility made it difficult to analyze production performance, evaluate waste levels and optimize processes efficiently. Noble Foods, therefore, required a scalable, automated solution that would eliminate manual record keeping and provide reliable, real-time production data.

The implemented solution centers around the SysTec IT6000E weighing indicators, chosen for its flexibility, customizable programmability and powerful communication capabilities. The system architecture connects mechanized poultry processing lines and pallet box scales via LAN to a central host PC and database server, creating a unified data environment.

Integration of Mechanized Processing Lines
For the mechanized production lines, the SysTec IT6000E weighing indicators were connected directly to the existing digital load cells. This configuration allows weight values to be captured dynamically while the line remains in motion.

The SysTec weighing electronics process the weight signals in real time, apply customized logic tailored to Noble Foods’ workflow and transmit the validated data directly to the central database.

This real-time data acquisition ensures continuous monitoring of production output without interrupting operations. It provides management with immediate insight into performance levels, throughput and deviations, significantly improving operational transparency.

Digitalization of Pallet Box Weighing
In addition to line integration, platform scales used for pallet boxes were upgraded with intelligent identification and labeling functionality. Each weighing station was equipped with an RFID reader to identify the operator securely before weighing begins. Once a pallet box is placed on the scale, the IT6000E records the gross weight together with operator identification, timestamp and product category, for example work in progress (WIP), finished product or waste.

Following the weighing process, a label printer generates a 2D barcode label that is applied directly to the pallet box. This barcode can later be scanned for tracking and traceability purposes. The integration of wireless barcode scanners ensures seamless data flow across different production stages.

All recorded information is transmitted to the host PC and stored in a central database, where it can be accessed for reporting, traceability and performance analysis.

 

One of the key benefits of the implemented solution is the creation of a centralized data infrastructure. All IT6000E weighing indicators communicate with a host PC connected to a database server, enabling consistent data storage and structured analysis.

Live dashboards provide real-time production visibility, while stored data can be evaluated for batch tracking, waste analysis and process optimization. This level of transparency supports faster decision-making and strengthens quality assurance procedures.

By consolidating production data from multiple sources into a single system, Noble Foods has laid the foundation for a fully digitalized production environment.

Summary
The flexibility of the IT6000E weighing indicators was essential for the success of the project. Its free programmability enabled the development of efficient applications tailored to Noble Foods’ operational requirements. During system implementation, functional adjustments could be introduced easily, ensuring smooth commissioning.

In addition, the weighing indicators’ versatile communication interfaces allowed straightforward integration of RFID readers, barcode scanners and label printers. The IT6000E weighing indicators’ ability to process data in real time makes it particularly suitable for dynamic production line environments where uninterrupted operation is critical.

Building on the success of the initial implementation, Noble Foods is now evaluating further expansion of the system. Planned developments include monitoring additional upstream mechanized lines, capturing data from further processing and storage areas, and consolidating all relevant information into a unified platform that covers the entire product flow from goods in to goods out.

• High operating comfort: Simple multilingual operator prompting, bright 5.7“ TFT color display with wide viewing angle and large-character weight display, numeric keyboard
• W&M approved use as a non-automatic and automatic weighing instrument is possible (approved in the EU, USA, Canada, etc.)
• Universal use: numerous standard application programs available
• Customizable: free programmability
• Robust: stainless steel housing (ingress protection IP69K)
• Ex-area: for hazardous areas SysTec offers the IT6000E Ex2/22
• Various designs: wall-mount / desktop version as well as panel-mount version
• Interface options for PC networks and printers, as well as fieldbus connection via Modbus TCP
• High operational security: data storage power-fail safe, password protection, battery-backed real-time clock, remote diagnostics possible via Internet
  
  
  Product Page: IT6000E
   

• SysTec IT CONFIGURATOR 
• SysTec PC ReadIT for the storage of serially transmitted data strings from one or several weighing indicators
• SysTec RTC WIN development platform to create a customized software solution