Combination scales are a critical component of packaging lines. A combination scale, also known as a multihead weigher, functions as an automatic weighing and filling machine, precisely measuring or counting weighments to be bagged, boxed, put in trays, or otherwise packaged. Greater accuracy and speed at the scale lead to improved productivity for the entire packaging line. Partial or total failure at the scale leads to costly downtime.
What is the real cost of downtime, in dollars, for your business?
Calculating the Cost of Downtime
The accuracy of a scale largely relies on combination theory. The greater the number of weigh heads on a scale, the more possible combinations available. On average, each weighment for packaging is comprised of 3 to 5 weigh heads. The next weighment will be compiled using the remaining, unused weigh heads to compute the most accurate weight possible. More possible combinations mean greater accuracy and reduced product giveaway.
| Weigh Heads | Combinations |
|---|---|
| 1 | 2 |
| 2 | 4 |
| 3 | 8 |
| 4 | 16 |
| 5 | 32 |
| 6 | 64 |
| 7 | 128 |
| 8 | 256 |
| 9 | 512 |
| 10 | 1024 |
| 11 | 2048 |
| 12 | 4096 |
| 13 | 8192 |
| 14 | 16384 |
If you have a 14-head combination scale, and one weigh head is inhibited, you reduce your possible combinations from 16,384 to 8,192. This is a substantial change in accuracy. For this example, the scale in question is weighing cashews. Let’s estimate that the loss of one weigh head leads to 0.5g in product giveaway per weighment. If you run your scale at 60 weighments per minute, you will be giving away about 31 pounds of product per 8-hour shift. With a current market value of $7.50 per pound of cashews, that is $232.50. The cost of this giveaway increases if you run at higher speeds, have multiple shifts, are packaging a particularly expensive product, or have multiple weigh heads inhibited. The impact on your bottom line will add up quickly.
The cost of one weigh head of your combination scale being inhibited is substantial. The cost of your entire scale going down is catastrophic. Production for that packaging line will stop completely. In the best-case scenario, your supplier will have a trained service professional onsite within 24 hours. Extended travel time and lead time on critical parts will compound the cost of downtime to your business.
Minimizing Downtime
According to PMMI’s 2025 Embracing Operational Readiness report, 78% of packaging professionals selected productivity as their top priority when surveyed. As demonstrated, the operational wellness of your combination scale plays a major role in the overall productivity. There are several actions that you can take to minimize downtime.
- Spare Parts: Keep critical spare parts on hand. Critical spare parts include those necessary for your multihead weigher to function. Power supplies are recommended spare parts. Also, keeping at least one spare actuator on hand at all times is a best practice. In the event of a general actuator failure, where weigh heads are inhibited and an actuator repair has been neglected, production levels, as well as the speed and accuracy of your machine, will be significantly reduced. In these instances, it’s best to replace the actuator.
- Preventative Maintenance: Develop and stick to a comprehensive preventative maintenance plan. Monthly, semi-annual, and annual inspections of your combination scale will detect early warning signs of potential part or machine failure and extend equipment lifetime. It is important to ensure that cost-saving measures do not compromise the quality, performance and longevity of your machine for the sake of short-term gain.
- Preparing Your Team: Ensure your operators and maintenance personnel are properly trained is a key component in minimizing downtime. Proper training ensures that all operators are following best practices. Training maintenance personnel enables them to change out parts and performance preventative maintenance which minimizes downtime.
Invest in Uptime
The most reliable solution to minimizing the downtime of your multihead weigher is to invest in reliable equipment. Yamato is the word leader in combination scales. Yamato DataweighTM scales offer the ideal combination of accuracy and speed. These advanced automatic weighing scales feature patented Ultra Heavy Duty load cells capable of withstanding 150 kilograms (330 pounds) of force while maintaining accurate resolution to 1/100 of a gram.
Maintaining peak performance extends beyond your initial investment. Minimize downtime with quick-turnaround access to Yamato genuine parts, stocked at facilities in the United States and Mexico for fast delivery. Most critical parts arrive within 24 hours of order. Same day shipment is another option for some critical components.
From basic operation to advanced troubleshooting, Yamato offers tailored training that helps your team get the most from your Yamato combination scale. Training programs can be offered at your facility or in on of Yamato’s dedicated training spaces in Grafton, Wisconsin, or Lake Forest, California.
Yamato Corporation has 17 dedicated, trained service technicians located across North and South America. This allows for quick deployment in case of emergency. Additionally, preventative maintenance services are available and can be tailored to fit your needs and schedule.
By understanding and addressing the costs associated with downtime, you can make informed decisions to enhance productivity and profitability. To learn more about how to reduce costly downtime, contact us about advanced automatic weighing solutions.