Established in 1984 Shawpak Systems prides itself on providing high level technical sales and support to our valued customer base. Offering solutions for Product Inspection, Packaging and Hygiene equipment sales and after sales support including certified customer training on site or at our Centre of Excellence training and demonstration facility.

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In Motion Weighing

In Motion Weighing is the continuous measurement of product weight during production without stopping the line, enabling real-time quality control and compliance verification. Shawpak Systems Ltd, based in Oakville, Ontario, supplies and supports in-motion weighing equipment for food processing, meat operations, and manufacturing facilities across North America, helping operations maintain consistency, reduce waste, and meet regulatory standards.

The Challenge: Balancing Speed with Accuracy in High-Volume Production

A mid-sized meat processing facility near Oakville faced a recurring problem. Their packaged products were inconsistent in weight. Some packages came in under target, risking customer complaints and potential regulatory action. Others exceeded target significantly, eating into margins with every unit produced. The operation ran at high speed - hundreds of packages per hour - making manual sampling inadequate. Line stops for quality checks cost time and money. They needed a way to verify weight continuously without slowing production.

The facility manager consulted with Shawpak Systems Ltd to understand what options existed. The core issue was not just detecting errors after the fact, but catching them in real time so operators could adjust fill weights or reject problem batches before they left the facility. For a food processor in Ontario or anywhere across North America serving retail chains with strict specification tolerances, this was not optional - it was essential to contract compliance and customer retention.

The Approach: Integrating In Motion Weighing into Production Workflow

Shawpak Systems Ltd conducted a thorough site assessment. The technical team evaluated the production line speed, package size variation, environmental conditions (temperature and humidity swings in the facility), and existing control systems. Rather than recommend a single solution, they outlined the trade-offs:

• High-speed checkweigher systems with digital output, best for facilities requiring sub-gram accuracy and real-time data logging
• Integration with existing PLC (programmable logic controller) systems to automate rejection of out-of-spec packages
• Statistical tracking and reporting to identify upstream causes of drift
• On-site training for operators and maintenance staff to calibrate, troubleshoot, and interpret data

Shawpak Systems has built its reputation on technical advisory and equipment selection consultation. Rather than pushing the most expensive option, they matched the facility's actual requirements: the line speed was 400 units per minute, accuracy tolerance was plus-or-minus 2 grams, and the operation needed documented evidence for third-party audits. Shawpak sourced equipment capable of 200 measurements per second, with data logging to a cloud-based system accessible from the plant manager's office.

Continuous measurement during production is not about perfection - it is about catching drift early, understanding where it happens, and fixing the cause instead of managing the waste.

The installation included integration with the facility's existing fill machine, sensor calibration with certified weights, and a full day of on-site training. Shawpak Systems' team demonstrated how to read the statistical reports, set alarm thresholds, and respond to warnings before product quality degraded.

The Result: Measurable Improvement in Compliance and Efficiency

Within the first month, the data revealed a pattern. Morning shifts showed gradual weight creep beginning around hour three of operation, caused by a partially worn valve in the fill head. Before this system was installed, the operation would have discovered the problem only when customer complaints arrived. Instead, the facility prevented hundreds of out-of-specification packages from shipping.

Key outcomes included:

• Weight variance reduced from plus-or-minus 4 grams to plus-or-minus 1.2 grams, tightening product consistency
• Reduction in package rejects due to weight by approximately 18 percent, saving material cost and labor in rework
• Documented audit trail satisfying customer and regulatory audits without manual sampling
• Preventive maintenance triggered by trend analysis, extending equipment life by identifying issues before failure
• Operator confidence in line performance increased, reducing the need for supervisory oversight during routine production

The facility's experience reflects broader industry practice. Facilities in Oakville and across Ontario and the wider North American market have found that real-time measurement systems pay for themselves within 12 to 18 months through waste reduction and compliance efficiency alone. For operations handling food, pharmaceuticals, or regulated manufacturing, the risk cost of non-compliance far exceeds the technology investment.

Shawpak Systems Ltd continues to support this facility with after-sales service, parts distribution, and periodic recalibration. When a sensor drifted six months after installation, a call to Shawpak resulted in same-day technical guidance and next-day parts delivery. That level of support is built into Shawpak's model - they view themselves as long-term partners in production reliability, not one-time equipment suppliers.

If your facility operates high-speed production lines and needs to verify product weight without interrupting flow, Shawpak Systems Ltd brings both the technical equipment and the advisory expertise to design a solution that fits your operation. Contact Shawpak to discuss your specific requirements and explore how continuous measurement can improve your product consistency and compliance posture.