Greenyard Frozen Belgium, a major producer of frozen fruits and vegetables, has taken significant steps to improve production accuracy and reduce waste across its high-speed packaging lines. Faced with chronic product overfilling – up to 40 grams extra per one-kilogram bag – Greenyard sought a precise, automated alternative that could eliminate unnecessary giveaway while maintaining strict weight compliance. The solution came through a strategic partnership with Mettler-Toledo and the integration of intelligent C33 PlusLine dynamic checkweighers equipped with smart fill level adjustment.

Traditionally, Greenyard’s process involved bulk vegetables moving through metal detection before passing to checkweighers for weight verification. Manual adjustments proved ineffective, resulting in tons of wasted product annually. The introduction of smart feedback control changed this. The C33 system continuously monitors average package weight and automatically fine-tunes the multi-head weigher’s fill margin – reducing the overfill buffer from 40 grams to just 10 grams. Following a successful trial, Greenyard rolled out the technology across all six small-packaging lines, supported by operator training and on-site configuration by Mettler-Toledo specialists.

The intelligent system goes beyond weighing; it dynamically adjusts filling weights in real time, keeping packaging consistently close to target without risking underfill. “The results were so convincing that we decided to replace four older devices and integrate this function across all lines,” explains Dominiek Vierstraete, Technical Manager at Greenyard Frozen Belgium.

The results speak for themselves. Overweight percentages on one line dropped from 0.69% to 0.14%, and from 0.30% to 0.11% on another. At 60 packs per minute, this equates to around 1.8 kilograms of product saved per minute. Beyond material savings, the system has improved operational efficiency by reducing manual intervention and stabilising production performance.

Mettler-Toledo’s support was key to maximising the technology’s impact. From initial testing and configuration to training and ongoing service, the company ensured Greenyard could fully leverage the new capability. “Margins are under pressure and every gram counts,” notes Mari Bögels, Account Manager. “Most customers see their investment returned within months.”

For Greenyard, the experience confirms the value of smart inspection technology – reducing waste, cutting costs, and contributing to a more sustainable, efficient production environment.