SysTec Systemtechnik und Industrieautomation GmbH (Germany) - SysTec Weighing Solutions for Poultry Processing Lines at Noble Foods

Noble Foods is one of the UK’s leading producers of poultry and egg-based products. Operating highly automated production facilities under stringent quality standards, the company requires precise and transparent production data across every stage of its processes. As production volumes increased and digitalization requirements continued to evolve, Noble Foods recognized the need to modernize its weighing and data acquisition infrastructure.

SysTec’s UK partners Stringer & Co Scales Ltd and Weighing Technology Services Ltd (WTS) implemented a fully integrated weighing solution. The system captures reliable production data from both mechanized poultry processing lines and platform scales used for pallet boxes. At the core of the solution are powerful SysTec IT6000E weighing indicators combined with a tailored software application based on the SysTec RTC WIN  development platform.

Key Facts:

• Integrated production data acquisition from mechanized poultry processing lines and pallet box weighing stations
• Real-time weight capture during production
• Operator identification via RFID; 2D barcode label printing
• Connection to central database

The Initial Situation:

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 Weighing Solution:

The implemented solution centers around the SysTec IT6000E weighing indicators, chosen for their 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.

Centralized Data Management and Real-time Reporting:

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.