Routine Testing Guide

Balance and
Scale Routine
Testing for Reliable
Weighing Results

Routine Testing of Balances and Scales

How to Do It Correctly
 Why Is It Important to Routinely Test Balances and Scales?
Routine Testing Guide

How much time do you spend thinking about the accuracy of your laboratory
balance or industrial scale? Probably not much! However, over time the
performance of weighing equipment can change due to environmental
changes, wear and tear, or non-apparent damage.

Routine testing of balances or scales in-between scheduled calibrations helps to maintain accuracy by ensuring
early detection of non-conformance with weighing process requirements so that corrective action can be taken in
a timely manner.

If testing isn’t performed correctly or not done at all, it can lead to:
• Undetected inaccurate weighing results because the device isn’t performing properly,
• Inferior results or product quality, process and audit issues,
• Repetition, product rework or recalls.

Routine testing by the user, along with periodically scheduled calibrations by a service technician, significantly
reduces the risk of inaccurate weighing results.

Figure 1: Routine balance and scale testing ensures consistently accurate weighing results.

How to Make Sure You Are Not Testing Too Often or Too Little?
A traditional approach with — often daily — routine testing at multiple points in the operating weighing range can
take a great deal of time and effort and therefore staff resources, and may not even provide any meaningful met-
rological information.

Discover what is really essential for testing your laboratory balances or industrial scales and how to put routine
testing into practice to ensure your weighing results are accurate each and every day.

2 Routine Testing of Balances and Scales

METTLER TOLEDO
Calibration, Adjustment and Routine Testing —
What’s the Difference?

Calibration, adjustment and routine testing are all vital to maintain weighing accuracy. Weighing instruments
undergo a certain amount of wear and tear over time as a result of frequent usage. It’s essential therefore that
any balance or scale is calibrated on a regular basis, and that adjustments or corrective actions are made
when necessary.
Service Technician

Calibration

Internal Routine
Adjustment Testing

Device User

Figure 2: The combination of calibration with preventive maintenance, routine testing and internal adjustment, (if applicable)
­ensures consistently accurate weighing results.

Calibration and Adjustment by a Service Technician

A calibration is performed by a qualified technician at regular intervals using certified test weights. The frequency
should be based on a risk assessment. In most cases calibration is performed once or twice a year. A calibration
assesses the device’s performance under operating conditions on site and must quantify measurement uncer-
tainty, which consists of assessing the error of indication, the influence of eccentricity and the repeatability.

Figure 3: When calibrating a balance or scale the service technician uses certified test weights.

Routine Testing of Balances and Scales

METTLER TOLEDO
3
 While calibration states how a weighing device behaves, adjustment changes its behavior. Adjusting an instru-
Routine Testing Guide
ment means modifying its indications in a way that allows them to correspond — as much as possible — to the
weights applied.

Internal Adjustment by the Balance or Scale

Automatic adjustment mechanisms built into weighing instruments consist of one or more reference weights and
a loading mechanism. Such a mechanism conveniently tests and adjusts the sensitivity of the weighing device
and is used to compensate for the impact of temperature changes on a measurement. However, although such
internal mechanisms allow a reduction in the frequency of tests with external reference weights, periodic perfor-
mance verification with external weights is still required.

Routine Testing by the User

Routine tests are measures undertaken by the instrument user to monitor performance and, if apparent, identify
potential problems between calibrations. They are conducted to verify a device’s performance over time. By
uncovering malfunctions early, such tests help to eliminate surprises at the next calibration service.

Minimum Weight
Routine
testing
Smallest net weight
Calibration

Adjustment Weighing
(by service) performance

Calibration period Calibration period

Time
Initial As-found As-left As-found
calibration calibration calibration calibration
Figure 4: Visualization of calibration, adjustment and routine testing over time.

4 Routine Testing of Balances and Scales

METTLER TOLEDO
The Four Pillars of Routine Testing

To outline the details of routine testing of balances and scales, four pillars need to be considered.

ROUTINE TESTING

4. Test Tolerances
1. Test Frequency

2. Test Methods

3. Test Weights

User Training
Figure 5: The four pillars of routine testing of balances and scales.

1. Test Frequency

The recommended frequency of routine testing for any given balance or scale will increase depending on the risk
and consequence of inaccurate results on the business and / or the health risk combined with the ability to trace
back errors. Therefore a risk assessment needs to be performed.

The risk of inaccurate results can be assessed by answering the following questions:
• Business impact:
What is the impact of wrong or inaccurate weighing results on your business process? Consider loss of mate-
rial and time, out of specifications, rework, production stop, fines, product recall, unhappy customers, loss of
reputation, etc.
• Consumer impact:
What is the impact of wrong or inaccurate weighing results on people, animals or the environment?
• Probability of detection:
Is there a chance of detecting a wrong or inaccurate weighing result immediately and easily?

The results of this risk assessment influence the frequency of routine testing. Therefore, the higher the risk,
the higher the frequency needs to be.

Do you need help performing such a risk assessment? Our GWP® Verification service includes a risk
assessment—next to all other elements needed for defining your individual routine testing plan.
Learn more on page 8.

Routine Testing of Balances and Scales

METTLER TOLEDO
5
 2. Test Methods
Routine Testing Guide

To verify a device’s weighing performance, tests should be conducted for sensitivity, repeatability and eccentric-
ity. Sensitivity testing should be performed most often as it is a low-error, simple procedure, followed by repeat-
ability and eccentricity testing.

Sensitivity Test
Sensitivity tests are an integral part of the functional control of a measurement device. The sensitivity compares
the indicated value of a weight versus the defined value for that weight. Measuring sensitivity is quick and
simple. For devices with an activated built-in automatic adjustment mechanism, sensitivity tests with external
weights can be carried out less frequently.

Repeatability Test
Repeatability tests are carried out less frequently than sensitivity tests, however they are important when weigh-
ing small samples because in low weighing ranges, repeatability is the largest contributor to measurement
uncertainty.

Repeatability is a measure of the ability of a balance or scale to supply the same result in repetitive weighings
with one and the same load under the same measurement conditions. Repeatability is usually measured by per-
forming 6 to 10 replicate weighings using the same test weight.

Note: Repeatability is highly affected by the ambient conditions (drafts, temperature fluctuations and vibrations)
and also by the skill of the person performing the weighing. Therefore, the series of measurements must be car-
ried out by the same operator, in the same location, under constant ambient conditions and without interruption.

Eccentricity Test
Eccentricity tests are recommended only when performing weighing processes
of higher risk and very tight weighing tolerances. The purpose of the eccentric-
ity test is to ensure that every eccentric load deviation (corner-load deviation) is
within the weighing tolerances. The eccentricity test assesses the deviation of the
measurement value through off-center (eccentric) loading. Eccentricity errors can
be minimized by handling the sample correctly, e.g. placing it in the center of the
weighing pan and by using accessories, such as ErgoClips.

Standard Operating Procedures for Routine Testing

Figure 6: The eccentricity test is
SOPs for sensitivity, repeatability and eccentricity testing are available to down- being performed in the center of
load free of charge, and help to ensure tests are performed correctly with few the weighing pan and in its four
quadrants.
errors and in less time.

Download our freely available SOP recommendations for sensitivity, repeatability

and eccentricity tests at:

www.mt.com/gwp-testing-SOP

6 Routine Testing of Balances and Scales

METTLER TOLEDO
3. Test Weights

METTLER TOLEDO offers a wide range of suitable test weights in all required
weight classes for routine testing of balances and scales. But which ones are
right for you?

GWP®1) states that only two test weights are needed for routine testing of balances and scales.
A smaller weight is needed for the repeatability test, which typically should be about 5% of your
device’s capacity.
A bigger weight is needed for the sensitivity and eccentricity test, which should normally be:
• For device capacities up to 60 kg: 100% of the device’s capacity.
• For device capacities above 60 kg: 33% of the device’s capacity.
Both weights are rounded down to the next available OIML/ASTM denomination.

Specially designed weight sets like the CarePacs® for laboratory balances only contain two test weights,
which can be selected to match your balance. Testing with just two weights saves a considerable amount
of time. In addition, purchasing and recalibration costs are significantly reduced.

Figure 7: METTLER TOLEDO offers a wide range of suitable test weights in all required weight classes for routine testing
of balances and scales.

www.mt.com/weights
www.mt.com/carepac

1) GWP (Good Weighing Practice™) is a global standard that ensures consistent accuracy, quality and compliance in any weighing pro-
cess. Established in 2007 by METTLER TOLEDO, GWP is a standardized methodology for the secure selection, calibration and operation
of balances or scales. GWP’s risk-based approach ensures that all your weighing devices meet your own accuracy requirements and
adhere to quality standards such as ISO, GMP and GLP. It is applicable to new or existing weighing devices from any manufacturer in
any industry or workplace.

Routine Testing of Balances and Scales

METTLER TOLEDO
7
 4. Test Tolerances
Routine Testing Guide

After performing the tests, the results need to be analyzed: Are they within your tolerances? Therefore, test toler-
ances need to be defined for each of the test methods.

GWP offers two limits of performance verification based on the concept of tolerance. The GWP® Verification pro-
vides concrete, ready to implement tolerances for the two levels for each test method (learn more in chapter 5).

The warning limit indicates that the device is not out of tolerance yet — but the safety margin has decreased. The
balance or scale can still be used, but METTLER TOLEDO Service should be contacted for a calibration combined
with an adjustment, if needed. The control limit specifies when the device is out of tolerance and no longer fit-for-
purpose. In this case, the balance or scale must be taken out of operation. Contact METTLER TOLEDO Service to
assess the next steps.

5. How to Define Your Routine Testing Plan

Having learned what the four pillars of routine testing are, how can these be defined for your balances and
scales? To do so, METTLER TOLEDO offers the GWP® Verification service which helps to maintain consistent
quality and optimized costs by providing you with a risk-based calibration and routine testing plan. This indi-
vidual plan includes the method, weights, tolerances, frequency, and standard operating procedures (SOPs) for
routine testing, along with the ideal service schedule. It also assesses whether or not the measured performance
of your balance or scale satisfies your process and quality requirements and then documents the measurement
range in which you can achieve accurate and reproducible results. Finally, GWP® Verification provides you with
additional security and regulatory-compliance documentation to pass audits.

www.mt.com/gwp-verification

Figure 8: GWP® Verification evaluates the accuracy of

balances and scales and provides information for regular
calibration and routine testing.

8 Routine Testing of Balances and Scales

METTLER TOLEDO
User Training

Today’s laboratory or production floor manager is not only responsible for ensuring accurate results and that
measuring equipment is regularly calibrated and properly maintained, they are also responsible for ensuring staff
are properly trained.

Our standard and customized training packages for equipment operation and maintenance provide staff with the
necessary skills to conduct routine testing of equipment and maintain compliance.

Check out our free eLearning course “Balance Routine Testing” (applicable also for industrial scales). This online
training course provides practical information and tips on how to test a balance correctly, including how to
assess the frequency of routine tests, which test weights to use, how to perform each test step-by-step and how
to interpret test results — all for free and with a certificate of attendance for proof of competence.

www.mt.com/lab-elearning

Routine Testing of Balances and Scales

METTLER TOLEDO
9
 Automation and Digitalization: Schedule and Document
Routine Testing Guide
Routine Tests

As devices become “smarter”, procedures like routine tests are becoming more automated and documented.
METTLER TOLEDO’s Excellence Level Balances, for example, are equipped with the GWP Approved quality assur-
ance function. This function actively monitors the balance status regarding tests, adjustments, settings and
levelling. Whenever routine balance testing is due, it alerts users and guides them through the test procedures
step-by-step.

Figure 9: Excellence Level Balances go beyond weighing by supporting users with data management, traceability and regulatory
compliance.

All relevant data, including test results, is subsequently documented, and printed records are generated stating
the device’s weighing performance for full traceability.

10 Routine Testing of Balances and Scales

METTLER TOLEDO
Summary

Balances and scales play a critical role in research and development, quality assurance and production. Errors
in weighing cost time and money, due to rework, waste and product recalls. Violations of legal requirements
may result in audit findings or even cause damage to health and/or the environment.

In order to maintain consistent product quality and comply with standards and regulations, the performance of
balances and scales needs to be verified at regular intervals. Periodic calibration by a service engineer com-
bined with regular, scheduled testing by the user according to defined SOPs are the best way of maintaining
accuracy, ensuring that balances and scales always perform within defined process tolerances. More and more
laboratory and production floor managers are realizing that it’s both less expensive and more efficient to build
quality into results from the start, rather than discovering problems later on.

Routine Testing of Balances and Scales

METTLER TOLEDO
11
Visit Our Lab Library
For Guides, Webinars and White Papers

Get more information on

www.mt.com/lab-library

www.mt.com/balances
For more information

METTLER TOLEDO Group

Laboratory Weighing
Local contact: www.mt.com/contacts

Subject to technical changes

© 12/2021 METTLER TOLEDO. All rights reserved
30474320D
Group MarCom RITM640799 KA/MA