Weighing Guide

A practical
guide on
workflow
optimization

Efficient Weighing Workflows

In the Chemical Industry
Editorial & Content

Streamline Your Lab Processes

and Increase Your Productivity

Material Receiving Tankfarming R&D and Quality Control Lab Water Processing Production: Production: Packaging, Logistics
Engineering Labs Synthesis Blending, Filling

Dear Reader,

In today’s fast-paced world, the chemical industry is always striving to remain one step ahead,
delivering high quality products on time and on budget. This highly cost-sensitive area has an
intense focus on productivity and, simultaneously, must meet demanding quality control stan-
dards to stay competitive in the marketplace. As a result, there is ever-increasing pressure to
improve the efficiency of procedures – adopting lean processes and automation to try to accel-
erate time-consuming processes – while maintaining the highest possible product quality.

The chemical industry encompasses a variety of scientific fields – including fine, speciality,
bulk and intermediate chemicals, refining and petrochemicals, polymers and plastics, and dyes,
pigments and inks – across R&D, production and QC facilities. In every case, there is a need for
cost-effective solutions to streamline operations. This guide discusses how optimum efficiency
and productivity can be achieved by carefully analyzing laboratory procedures, identifying –
and, as far as possible, eliminating – inefficiencies, and introducing standardized processes.
Weighing is the first step in virtually any analytical procedure. Automation is the solution for
many typically occurring issues in chemical industry workflows, helping to optimize procedures,
eliminate the potential for manual errors, and ensure high quality standards are met. Six typical
workflows are discussed and process improvements suggested.

METTLER TOLEDO

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Editorial 2

1 Applications and Workflows 4

1.1 Formulation 4
1.2 Moisture Content, Loss on Drying (LoD), Loss on Ignition (LoI) 10
1.3 Particle Size Analysis and Distribution 14
1.4 Density Determination of Solids and Porous or Viscous Materials 17
1.5 Sample Preparation for Titration (including Karl Fischer) 19
1.6 Preparation of Reference Substances for HPLC or GC Analysis 23
2 General Process Optimization 26
2.1 Accuracy and Routine Testing 26
2.2 Data Integrity, Connectivity and Workflow Guidance 27
2.3 External Physical Influences and Cleaning 28
2.4 Fume Hoods, Glove Boxes and Safety Cabinets 29
2.5 User Ergonomics 30

3 Conclusions 31

4 Useful Links 31

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3
 1 Applications and Workflows
Efficient Weighing

The chemical industry is highly diverse, from the supply of fine, speciality and bulk chemicals, to the refining of
petrochemicals and the manufacture of polymers, plastics and pigments. Each of these segments incorporates
a variety of applications and workflows, all of which can benefit from the latest advances in weighing technology
and laboratory software. This guide describes some of the most common workflows, identifying potential pain
points and highlighting possible solutions.

1.1 Formulation
Workflow description
R&D laboratories doing formulation and totalization typically undertake mini production scale, scale-up and
repeatability studies. This can involve design of experiments (DOE) studies and the preparation of reaction
mixes, small test batches, working solutions or even finished goods. Workflows will generally include:
• Frequent recalculation of recipes to achieve target weights for a given batch size.
• Precise weighing of difficult components, for example, pigments and flavors.
• Tracking all compound weights and the composition of mixtures.
• Reporting and archiving for quality control of the final product.

Library – database
of formulation, recipe,
solution, media
Labeling
(in document or SOP)

Recipe standardized Weighing compounds Refill in Report

(e.g. to 1 l / 1,000 g) bottle archive
All directly in one
beaker

Recalculate Dissolving Adjust pH

weights Using weighing paper

Higher accuracy
+ needed for some
compounds

Figure 1: Typical formulation workflow.

Workflow challenges and potential improvements

Formulations could consist of 30 or more separate
components, and the formulation process itself can
be labor-intensive and require concentration; even the
most skilled technician might spend over an hour and a
half for preparing certain mixtures. During this process,
weighing is often performed with a variety of labware
– from weighing papers to five liter beakers – although
weighing boats are often chosen for convenience, as
they make it easier to correct erroneous dispensing.

Regardless of the labware used, there are several factors

which can influence the weighing, such as air currents,
electrostatic charges and magnetic stirrers. These can
give rise to issues – such as difficulty taring the balance,
drifting and unstable readings, longer settling times and
poor weighing accuracy – reducing productivity and,
potentially, requiring formulations to be repeated.

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Draft shields are often used to protect the weighing pan and the tare container from the influence of air currents,
particularly within fume hoods or safety cabinets, but these also have a number of drawbacks:
• The draft shield doors must be opened and closed several times during weighing operations – extending
the time required.
• The draft shield is an additional item to clean, often requiring several parts to be dismantled to allow
thorough cleaning.
• Bulky and/or heavy tare containers are more difficult to handle.

To ensure complete traceability, information crucial to the process must be recorded, such as the user ID, recipe
name, date and time of preparation, expiry date, batch number, compounds used, quantities required, toler-
ances, quantities dispensed and pH values. This will often take the form of handwritten component labels and
laboratory notebook records, in addition to instrument printouts of weights pH. The process is time-consuming
and prone to human error, potentially resulting in formulations having to be repeated.

Solutions
Many of these issues can be mitigated by choosing appropriate weighing equipment and accessories. Precision
balances capable of reading to three decimal places are ideal for the preparation of reaction mixes or small for-
mulation batches, while two place balances are perfect for preparation of solutions and production lots. Where
very small amounts of a compound must be weighed, an analytical balance is preferred. For process security,
barcode readers help to eliminate manual errors, ensuring accurate sample identification and traceability.

Figure 2: Three decimal places precision balances – like the XS603S – are ideal for the preparation of reaction mixes or small formulation batches.
A barcode reader ensures accurate sample identification and traceability.

METTLER TOLEDO balances equipped with a SmartPan™ weighing pan – for example, the XPE balance range –
enable precision weighing with the minimum of fuss, even in the presence of air currents. Stabilization times are
up to twice as fast, and up to a two-fold improvement in repeatability can be seen. There is no need for a draft
shield, even when weighing in a fume hood, making weighing easier and more ergonomic, saving an estimated
eight to ten seconds per component weighed.

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Efficient Weighing

Figure 3: The innovative SmartPan™ weighing pan of the XPE and XS precision balances minimizes the effects of air currents on the weighing cell
resulting in the dramatic improvement in settling time and repeatability. Even in a fume hood, 1, 5 and 10 mg models deliver results up to twice as
fast. Repeatability is improved up to two-fold.

Learn more
White Paper “Outstanding Weighing Performance – Even Under Harsh Conditions”:
www.mt.com/smartpan

This white paper describes the influences of air flow during the weighing process. Innovations in the design
of the weighing pan for precision balances and scales help to minimize any errors due to air drafts. The
results of weighing on the optimized design of weighing pan are compared with those obtained using con-
ventional weighing pans. The innovative SmartPan weighing pan makes it possible to deliver results up to
twice as fast, even under harsh conditions. As the speed and precision of weighing results (respectively
settling time and repeatability) is closely associated with the positioning of the balance, recommendations
on factors to consider in choosing the optimum location for the balance are also given.

Making users more comfortable can also make them more efficient, leading to increased throughput for many
laboratories. Placing the weighing terminal on a stand and adjusting the tilt to suit the user’s height makes the
display easier to read and helps users maintain a good posture, reducing stresses during prolonged weighing.

Figure 4: A terminal stand supports good posture by making your weighing processes as ergonomic as possible.

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Figure 5: Touch screen displays with large digits and an intuitive user interface bring comfort to your daily tasks.

For formulations with fewer, larger, heavier or bulk components, precision balances with 0.01 to 0.1 g resolution,
preferably with a large platform, are a suitable solution. If data capture and data traceability are not so important
and automation features are not needed, precision balances of the MS-TS or ML-T line are the perfect option.

Figure 6: Hardworking balance with a large platform for simple weighing tasks.

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7
 Many formulations require small quantities of components, for example pigments, to be weighed with high
Efficient Weighing
accuracy. Four or five decimal place balances are ideal for this task. METTLER TOLEDO’s XPE and XS analytical
balances are equipped with a SmartGrid™ hanging weighing pan. The minimal surface area of this weighing
pan design significantly reduces the effect of air turbulence in the weighing chamber compared to conventional
weighing pans for faster, more reproducible weighing.

Figure 7: The unique SmartGrid weighing pan of the XPE and XS analytical balances ensures fast results by substantially reducing stabilization times.

A draft shield with automatic doors can be used to minimize air flow within the weighing chamber of the analyti-
cal balance without inconveniencing the user. Hands-free balance taring can further accelerate weighing pro-
cesses. The overall effect is shorter stabilization times and faster results.

Figure 8: The doors of the draft shield can be individually opened, so dosing is relaxed and straightforward. Work can be carried out much faster
using truly ergonomic weighing processes, increasing productivity in the laboratory.

Do not let electrostatic charges influence the weighing process. The StaticDetect™ technology of the XPE ana-
lytical balances automatically recognizes electrostatic charges on the sample and/or its container, enabling the
use of antistatic measures such as a point electrode attached to the side of the balance to quickly remove any
charges that affect the accuracy of the weighing result.

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 Resulting force due to
static charge of sample

1.2 mg
Static Error

Mechanism for
static detection

Figure 9: StaticDetect technology analyzes the weighing signal to quantify any weighing error caused by electrostatic charges. If this error exceeds
a user-defined limit, the balance issues a clear warning on the terminal screen.

Some formulations require numerous components, some of which may need to be weighed using different
balances due to the varying amounts required. LabX® software can help to resolve some of the issues arising
from the use of multiple balances, enabling direct data transfer to and from a LIMS system and automatically
calculating the target amount for each component based on pre-programmed formulation recipes. The software
can then guide the user through the weighing process, eliminating manual transcription and calculation errors,
providing full traceability and enabling the generation of comprehensive weighing reports.

Figure 10: LabX software – compatible with XPE and XS balances – enables formulation storage and calculations, guiding the user through the
weighing process to reduce the risk of errors.

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9
 1.2 Moisture Content, Loss on Drying (LoD), Loss on Ignition (LoI)
Efficient Weighing
Workflow description
There are a variety of chemical processes that require the accurate determination of the moisture, organic and min-
eral content of polymers, beads, petrochemical goods, lubricants, pastes and other sample types. A defined range
of values is often specified, ensuring that both production processes and the final product meet the expected qual-
ity requirements. For goods marketed based on weight, it also helps to maintain cost-effective production.

The loss on ignition test is commonly used for mineral analysis. The sample is accurately weighed into a plati-
num crucible and placed in a muffle furnace at a temperature of 1,000–1,200 °C for 15–20 minutes to drive off
any volatile substances. After cooling in a desiccator, the weight is recorded. This procedure is repeated until the
weight becomes constant.

Project task ERP,

LIMS

Sample First Back

Sample Report
Sample weighing weighing
Sample archive
treatment
• drying
Source • ashing
aliquot Labeling • coating Calculation Analysis
• collecting
• …
(References)

Figure 11: Typical loss on drying (LoD), loss on ignition (LoI) workflow.

The loss on drying test, designed to measure the content of water and volatile matter, is similar, except that the
sample is dried in an oven at much lower temperatures, typically around 105 °C.

In both tests, several samples are run in parallel, taking

from a few hours to several days. Like any batch analy-
sis, this extends the time to results – creating time pres-
sures – and increases the risk of transcription or handling
errors leading to samples being mixed up. Samples must
also be treated identically, including target weighing and
analysis, and several calculation stages are required,
including dry/wet content analysis and pass/fail criteria.
For quality control purposes, data reporting and archiving
is essential.

Workflow challenges and potential improvements

There are a number of issues associated with LoD and
LoI analyses, which can be largely overcome by careful
choice of equipment and software.

• Large numbers of samples make the process laborious

and error-prone.
• Handling of small crucibles must be fast to prevent
uptake of humidity by the sample.

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• Data and result transcription/calculation accounts for up to 80% of weighing time.
• Human errors – such as mixing up samples, following the wrong standard operating procedure (SOP), or cal-
culation and transcription mistakes – reduce sample throughput and productivity.

Solutions
Speed and process security are essential for LoD and LoI analyses. Sample tracking via barcoded labels sim-
plifies sample handling and avoids any mix-ups. This can be particularly helpful when handling large sample
volumes at high throughput. For LoD LabX enables automatic barcode label printing and identification, as well
as avoiding the need for manual data entry and calculations. This ensure crucibles can be weighed in any order
without the risk of mix-ups. Weighing processes can be further accelerated by using a labware-specific container
holder, such as an ErgoClip, allowing rapid and safe positioning of the crucible to help prevent uptake of humidity.

Figure 12: XPE analytical balance – equipped with an ErgoClip Round Bottom Flask, a label printer and a barcode reader – makes LoD and LoI pro-
cesses faster and less error-prone, as well as offering user guidance and automatic data capture.

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11
 LoD and LoI analyses can be easily performed using XPE or XS analytical balances in conjunction with LabX soft-
Efficient Weighing
ware. Weighing methods programmed into LabX can be run through the terminal of the balance, guiding the user
through the weighing process to ensure adherence to SOPs. Methods can be paused at any time – freeing the
balance for other laboratory personnel – and information such as sample names, batch or lot numbers, initial and
final weights, calculated values and pass/fail results are automatically stored in the LabX database. Results are
automatically calculated, providing full traceability, and the final results report can be printed on an office printer.

Figure 13: XPE and XS balances with 1 mg or 0.1 mg resolution – for example, the XPE204 – are ideal for dry oven tests. Semi-automation of the
process through LabX software greatly simplifies both sample and data handling.

Straightforward in-process moisture analysis is vital in busy production environments. The faster testing can
be performed, the more samples can be checked in the same time, improving QC productivity and process effi-
cency. Much faster determination of moisture content can be achieved with alternative methods, such as Halo-
gen Moisture Analysis, which is easy to use and gives a direct result in a fraction of the time. Halogen Moisture
Analyzers (HMA) also operate on the principle of LoD, but moisture determination normally takes five to 15 min-
utes, compared to 2 to 3 hours using a drying oven. The other key benefit of HMA’s is ease of operation, deliver-
ing a direct measurement result with no calculations necessary.

Figure 14: Easy-to-use moisture analyzers, such as the robust HC103 with intuitive touchscreen operation, are ideal for in-process control in the
chemical industry.

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Advanced halogen technology provides fast heating and exact temperature control, generating precise, reliable
results in the shortest possible time. A high performance weighing cell, innovative hanging weighing pan and
readability up to 0.1 mg provide the best measurement performance. This is complemented by the easy-to-use
One Click Moisture™ graphical user interface – featuring real-time drying curves and control charts – which
enables smooth and fast operation, time after time.

Four decimal place moisture analyzers – such as the HX204 – are recommended for in-process testing of plas-
tic components, due to the low overall moisture content and resulting need for accuracy.

Figure 15: The HX204 four decimal place halogen moisture analyzer is ideal for in-process testing of plastic components. Placing the terminal and
printer on a stand saves valuable space on the laboratory bench and makes handling and reading easier.

Learn more
White Paper “Drying Oven vs. Halogen Moisture Analyzer”:
www.mt.com/oven-vs-hma

Loss on drying (LOD) methods are typically used to determine moisture content, with established reference
methods often based on drying ovens. Halogen moisture analyzers (HMA) are a fast alternative method
for LOD. This White Paper explains the key decision criteria surrounding the choice of method and provides
practical guidance on how to demonstrate that the two different methods (drying oven vs HMA) deliver
comparable results.

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 1.3 Particle Size Analysis and Distribution
Efficient Weighing
Workflow description
Particle size and distribution can have a significant impact on production processes, and is an important consid-
eration from a quality viewpoint. In many applications, the homogeneity of the particle size in both the raw mate-
rials – for example, grains, beads, pellets and powders – and the finished product must be kept within a specific
range. Maintaining the consistency of this important parameter is vital to ensure the quality of the process and
the properties of the final product, safeguarding its function and specification so that it is fit for purpose.

Project task ERP,

LIMS

Sample First Back

Sample Report
Sample weighing weighing
archive
(empty
sieves)
Source
aliquot Labeling Calculation Analysis
Sample +
sieving

Figure 16: Typical particle size analysis determination workflow.

Workflow challenges and potential improvements

The determination of particle size can be achieved by
a number of different sieve weighing approaches that
involve complex and time-consuming weighing. Like
LoD and LoI analyses, an extended and cumbersome
calculation process is required. Typically:
• Weighing processes are slow and prone to errors,
with several analyses performed at the same time.
• Batch analysis delays the time to result, creating
time pressures.
• The particle size distribution is a lengthy calculation
process that includes weighing the total sample
and the individual fractions in each sieve/pan,
plus retrieval of the sieve weights.
• Balances need to be robust enough to withstand
a busy production environment.
• Reporting and archiving processes are often
required for quality control purposes.

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Solutions
Balances with 0.01 to 1 g resolution, preferably with a large weighing pan, are ideal for particle size distribution
analyses. They offer a broad weighing range to handle the large, heavy sieves and enough resolution to analyze
smaller fractions with smaller sample sizes.

Figure 17: Fast and easy particle size distribution analysis on a rugged one or two decimal place balance.

The use of an ErgoClip Sieve can also be advantageous, making it easier to position sieves safely and securely
for weighing.

Figure 18: The ErgoClip Sieve supports the positioning of the sieves on the balance.

LabX software offers one-click access to sample-specific sieve analysis protocols and ensures that the analyst
always has the right SOP at their fingertips. Step-by-step instructions and automatic detection allow sieves to
be weighed consecutively without needing to touch a button. This eliminates the need for time-consuming and
error-prone data transcription and calculations, streamlining the process and providing full traceability. Printable,
A4 format, PDF reports are generated, containing all the relevant information, which are easy to archive and
search, and are tamper-proof.

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Figure 19: The LabX sieve analysis application semi-automates the process, delivering fully traceable results and generating customizable reports
with graphs of the results.

Figure 20: LabX software calculates results – such as distribution percentage and d50 grid size – automatically. A customized report including
graphs can be printed at any time.

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1.4 Density Determination of Solids and Porous or Viscous Materials
Workflow description
Density determination is another important means of establishing the quality of raw materials and finished
products, ensuring specifications are met. In the chemical industry, it is likely to be applied to testing of solid
samples, for example, alloys and polymers, liquids – including light oils – and pastes, such as lubricants. Den-
sity determination is based on Archimedes‘ principle, which states that a body immersed in a fluid apparently
loses weight by an amount equal to the weight of the fluid it displaces. It can be determined by several methods,
including the buoyancy technique, the displacement principle or by pycnometer.

Production lot Quality certificate

Request for analysis Release or block of batch

Weighing Weighing in
at air auxiliary liquid

Calculation Report (certificate) /

Sample
Sample of density archive
Sample

Figure 21: Typical density determination workflow.

Workflow challenges and potential improvements

Density determination methods must be reliable to ensure high batch accuracy.

• Gravimetric density determination depends on accurate weighing measurements.

• ISO 1183-1 compliance is frequently necessary. This requires a four place balance, a thermometer with
0.2 °C graduations, a maximum suspension wire diameter of 0.5 mm, and accuracy within ±3% of the
customer’s process tolerance.
• Selection of the correct auxiliary liquid to ensure that it has a
density lower than the expected sample density. This avoids
situations where the sample floats on the auxiliary liquid and
is not fully wetted.
• Density calculations can be complex, and manual transcription
and calculation errors can potentially result in batch failures.

Solutions
METTLER TOLEDO offers a range of hardware and software
options for gravimetric determination of the density of solid, liquid,
porous and viscous substances. Density Kits – accepted as the
industry standard – are available for both analytical and precision
balances, and are easily mounted in a few simple steps. Their
rugged design and sturdy construction offer durability and ease
of use, making density determination by the buoyancy technique,
displacement principle or pycnometer method convenient and pre-
cise. In cases where the sample density is lower than the auxiliary
liquid density, the Density Kit basket may be reversed to ensure
submersion. METTLER TOLEDO analytical balances used with the
Density Kit fulfill – or even outperform – ISO 1183-1 requirements.

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17
 METTLER TOLEDO balances feature a built-in density determination application which guides the user through
Efficient Weighing
the procedure step-by-step, collects the results and calculates the density. Data can be transferred from the bal-
ance to a linked computer, or printed out. Reports can be customized to individual customers’ needs.

If data capture and data traceability are not so important and the balance is not connected to an overall system,
the MS balance range and Density Kit are ideal. For documentation purposes, a printer can be connected or data
can be exported via USB.

Figure 22: The MS204TS analytical balance works perfectly for occasional density determination or when data management is not at highest priority.

For solutions integrated with Enterprise Resource Planning (ERP) software and Laboratory Information Manage-
ment Systems (LIMS), plus pycnometer applications, the XPE analytical and Density Kit are the perfect solution.
Offering resolution between 0.1 and 1 mg and a built-in density determination application, they can be used
either with a printer or, for automated data capture and ERP/LIMS integration, with LabX software.

Figure 23: Density determination can be easily performed using XPE or XS analytical balances in conjunction with LabX software. Results are auto-
matically calculated and full traceability is provided.

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1.5 Sample Preparation for Titration (including Karl Fischer)
Workflow description
Titration is a commonly-used wet chemistry technique for the analysis of liquids and dissolvable solids. It has
many applications, including the determination of acidity, alkaline salts and some metal ions or, in the case of
Karl Fischer titrations, estimation of the sample’s organic bound water content.

Accurate sample preparation is crucial. Typically, a workflow for quantitative analysis of a dissolvable solid com-
prises the following steps:
• Placing the titration beaker on the weighing pan and taring the balance, then recording information such as
the compound ID, balance, date, time, etc., either manually, or via barcoded samples.
• Weighing the compound of interest into the beaker.
• Adding solvent to the desired quantity, e.g. 50 ml.
• Transferring the beaker to the titrator.
• Performing the titration.

Production lot ERP,

Request for analysis LIMS

Report
Archive Analysis
Weighing Labeling

Transfer
Source Add Sample weight
Samples Dissolving Titration
aliquot data to
Titrator

Figure 24: Typical workflow for quantitative analysis of a dissolvable solid.

Workflow challenges and potential improvements

Avoiding handling errors and the mix up of samples is
vital to avoid erroneous or inconsistent results, requiring
manual checking of sample IDs and data recording. Par-
ticular attention should be paid to:
• The inherent risk of transcription errors when manual
record keeping is employed.
• The potential for samples to become mixed up during
manual transfer between the balance and the titrator
if labels are incorrect or illegible.
• Incorrect transfer of the weighing results to the titrator,
generating incorrect data.

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 Solutions
Efficient Weighing
For Karl Fisher (KF) titration, samples can be prepared in syringes – samples for KF titration should be exposed
to air as little as possible to prevent humidity absorption. The sample preparation can be done very precisely by
gravimetric measurement. XPE or XS 0.1 mg analytical balances – such as the XPE204 – can be used with an
ErgoClip Syringe sample holder to simplify weighing of the sample weight in syringes.

Figure 25: The ErgoClip Syringe makes sample preparation for Karl Fischer titration straightforward.

When weighing into titration beakers, the risk of crossing samples can be eliminated by the use of a XPE205
analytical balance with SmartSample™ – an RFID reader and writer – and Smart Tags. Samples are automati-
cally tracked via their RFID Smart Tag and all relevant information, including sample ID, weight and titration
with SmartSample
method, is transferred to™
the tag for storage. Manual record keeping is eliminated.

*08628* WASTE

Import Data Weigh Transfer Titrate Export Data

• Paper
• Barcode Eliminate transcription errors asso-
• LIMS ciated with data input – all sample
information together with the weight
are wirelessly transferred to the chip
(SmartTag™) on the titration beaker.
• Live Display
No matter where you put your All sample information on the tag, • Printer
sample,all information stays on including the weight, is automatically • USB Stick
the SmartTag avoiding mix-up transferred to your Excellence titrator • Network
errors throughout your workflow. for simple and secure analysis. • Computer

Figure 26: The SmartSample weighing system for titration automation increases efficiency using RFID technology. Tags attached to the beaker
transfer sample information wirelessly, eliminating transcription and ordering errors.
www.mt.com/SmartSample

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After weighing, the sample is transferred to the titrator – for example the Excellence T9 Titrator with InMotion
Autosampler – which automatically reads the information from the Smart Tag, logs the sample ID and weight,
and starts the corresponding method, recording the results automatically.

Figure 27: The XPE205 balance with SmartSample RFID reader and writer and Figure 28: Close up of a SmartSample
RFID Smart Tags helps to ensure correct sample identification. weighing balance.

Figure 29: The Excellence T9 Titrator with InMotion Autosampler.

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21
 For total traceability of every step of the workflow, LabX software – compatible with XPE and XS balances, as
Efficient Weighing
well as the Excellence range of titrators – guides the user through the entire process, automatically recording
every result, transferring the weighing results via tag from the balance to the titrator and printing reports, ensur-
ing full data integrity.

Figure 30: An XPE balance and Excellence T9 Titrator connected to LabX software offer step-by-step guidance through the entire process and total
traceability of every step of the workflow.

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1.6 Preparation of Reference Substances for HPLC or GC Analysis
Workflow description
The preparation of reference standard and sample solutions is one of the most common tasks in an analytical
laboratory conducting quantitative analysis. This type of analysis will often be performed to determine the con-
centration and purity of ingredients, or to check for any impurities or contaminants, ensuring that any defined
limits are adhered to.

The workflow will generally involve a number of different steps:

• Solution preparation. Samples and standards are weighed on weighing paper or in weighing boats, trans-
ferred to a volumetric flask and diluted to volume.
• Serial dilutions are then performed to reach a concentration suitable for analysis.
• Analysis, for example by HPLC.
• Data storage.
• Interpretation of results and report generation.

Production lot ERP,

Request for analysis LIMS

Weighing Dissolving
Samples Release
Sample + filling to
a given volume

Source
aliquot Samples + filling to Dilution Labeling Analysis
a given volume

References Sample + appropriate

volume of liquid Report
archive

Figure 31: Typical workflow for preparation of reference standard and sample solutions.

Workflow challenges and potential improvements

This straightforward workflow can be improved in sev-
eral ways:
• Eliminating weighing paper/boats by direct dosing
into a volumetric flask, reducing the potential for
errors due to powder spillage during sample transfer.
Back weighing of weighing papers and calculations
become obsolete.
• Removal of electrostatic charges from the sample or
tare container using antistatic devices.
• Addition of a label printer to the balance, simplifying
sample and standard management.
• Reducing out-of-specification errors in volumetric
sample preparation by making the shift to mass-based
methods with enhanced concentration accuracy.
• The use of LabX software, which guides users through
every step of the process: dosing, calculations and
reporting.

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23
 Solutions
Efficient Weighing
Volumetric standard and sample preparation can benefit from METTLER TOLEDO’s analytical and micro-analyti-
cal balances – such as the XPE56 – offering readability of 0.001 mg, a capacity of 50 g and a typical minimum
net sample weight (USP) of 1.4 mg.

Figure 32: Dose directly into 10 ml volumetric flasks on a XPE56 micro-analytical balance equipped with an ErgoClip Flask micro, an ErgoClip Min-
Weigh Door micro and a draft shield. Transcription errors can be avoided by the addition of a printer.

ErgoClips allow you to safely position a vast range of tare containers – including HPLC sample bottles,
microfuge, PCR and test tubes and volumetric flasks – up to 100 ml in volume for direct dosing. To reduce the
impact of drafts in the weighing chamber, dosing can be performed through the MinWeigh Door micro draft
shield. For the highest process security, the latest sensor technology and built-in electrode option can be used
to detect and eliminate any electrostatic charges, while transcription errors can be avoided by the addition of
a printer, enabling labels to be printed at the time of weighing.

Gravimetric preparation of standards and sample solutions can help to reduce variability in the process.
XPE analytical balances can be upgraded to incorporate a Quantos liquid dosing module, enabling automated
liquid dispensing that meets the requirements of USP Chapters 41 and 841, improving accuracy and throughput.

Figure 33: Gravimetric sample preparation with an XPE analytical balance equipped with a Quantos liquid dosing module, enabling extremely
accurate gravimetric addition of liquids and solvents.

24 Efficient Weighing Guide

METTLER TOLEDO
 100 ml
100 ml
Solvent

50 ml
50 ml

5x Factor 2.5 in
substance consumption
solvent
waste 20 ml

10 ml

0 ml
0 mg/ml 2.5 mg/ml 5 mg/ml
Concentration
Figure 34: Save solvents (and money) by preparing smaller amounts of reference substances.

To help boost productivity, processes can be automated using LabX software, providing complete sample trace-
ability and data security. The software database stores details of all active substances and the concentrations
for stock solutions, and can be accessed remotely from any connected balance terminal without the need for
a directly connected PC. All process data is saved and reports can be printed at any time.

Figure 35: Quantos liquid dosing system and LabX software for increased productivity and accurate results, without the risk of manual errors.

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25
 2 General Process Optimization
Efficient Weighing

Balances are precision instruments requiring care and maintenance to ensure continued correct operation. This
plays a critical role in the reduction of day-to-day reproducibility issues.

2.1 Accuracy and Routine Testing

The first, and most important, step in any laboratory application or workflow is to ensure that all balances are
correctly calibrated and routine testing of equipment is up to date. Optimizing maintenance procedures and bal-
ance verification intervals will help to eliminate inaccurate readings and their knock-on effects, such as bad
batches and rejects. This avoids waste and the unnecessary associated costs.

Regular verification and control of weighing equipment is an essential part of ISO, GLP or GMP quality manage-
ment systems, ideally conforming to a risk management process. It ensures that instruments continually perform
reliably and to a high standard, meeting relevant specifications and fulfilling current regulatory demands. This
requirement is made clear in the OECD (Organisation of Economic Co-operation and Development) publication
Principles of Good Laboratory Practice, Chapter 4.2: Use, Calibration, and Maintenance of Equipment. Recent
changes to ISO 9001 focus strongly on processes and risk-based approaches, which require the chemical
industry to implement changes to achieve intended results.

Generally, laboratory balances are checked – dependent on the risk – for sensitivity, repeatability and eccentric-
ity. A risk-based approach helps to properly define which routine tests should be performed and how often. Once
adopted, the risk of a balance failing future calibrations is minimized.

METTLER TOLEDO developed GWP® – Good Weighing Practice™ – as a standardized scientific methodology
for secure selection, calibration and operation of weighing equipment. GWP’s risk-based approach ensures that
all balances meet process accuracy requirements and adhere to quality standards such as ISO, GMP and GLP.
Apart from routine testing recommendations, including the appropriate weights, GWP also recommends calibra-
tion procedures and METTLER TOLEDO’s globally-harmonized calibration service, based on EURAMET cg18; the
Accuracy Calibration Certificate produced, together with the GWP annex, provides a complete picture of the bal-
ance status, ensuring that it is not only calibrated, but also fit for the intended purpose. The message is clear;
calibrate your process, and not just the balance.

More information: www.mt.com/gwp

h ing St
eig an
W
da
The

rd

Ap
proved
Figure 36: The GWP Approved label is the highest quality label in weighing, which confirms that the balance has undergone a risk based assess-
ment (GWP Verification), defining and confirming the safe weighing range according to customer’s tolerances and specifications.

Learn more
Webinar “The Global Weighing Standard”:
www.mt.com/GWPWebinar

Part 1: Measurement uncertainty and minimum weight

Part 2: Routine testing of weighing systems

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METTLER TOLEDO
2.2 Data Integrity, Connectivity and Workflow Guidance
Data integrity refers to the maintenance and assurance of data accuracy and consistency over an entire workflow,
including secure, error-free data recording and its transfer into and out of Enterprise Resource Planning (ERP) soft-
ware and Laboratory Information Management Systems (LIMS). Accurate weighing is essential – the first step in
virtually any analytical procedure – and any errors at this point can have a profound impact on product integrity.

SOPs should be embraced, and workflow guidance given to all staff in order to increase data integrity. Mov-
ing from a manual to an electronic process, adopting automated procedures and data management software
that replaces laboratory journals, spreadsheets and even printouts, can also have a big impact. Fully electronic
processes with a single system log-on can be implemented, using LIMS to define a batch of samples for pro-
cessing, specify procedures and analytical methods, collecting and storing all data electronically. By adopting
fully guided, paper-free procedures, manual data entries, with the associated potential for transcription errors,
are eliminated. Data quality is improved, and all the technical controls necessary to ensure compliance with
GxP regulations for electronic records and signatures are incorporated. The time taken to perform a given task
is reduced, speeding up the overall process for a fast, efficient workflow.

Figure 37: LabX software integrates data capture for many laboratory instruments, working behind the scene to take care of all your data while you
concentrate on your analyses. Data can be automatically transferred to eliminate transcription errors and increase productivity. Processes and cal-
culations are guided, ensuring each user follows the same analytical process, helping to eliminate rework and waste.

Learn more
Webinar “The Importance of Data Integrity in a GxP Regulated Laboratory”:
www.mt.com/lab-data-webinar

This webinar will look at areas for assessment and improvement in data integrity, such as what constitutes
raw data when a computerized system is involved. Practical solutions to improve data management pro-
cesses and address data integrity weaknesses in a typical laboratory will be discussed.

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27
 2.3 External Physical Influences and Cleaning
Efficient Weighing
Balances are sensitive to external influences, which can significantly affect weighing accuracy. Typically, the sta-
bility and accuracy of the balance is influenced by:
• Rapid temperature changes, sunlight and temperature differences between the sample, weighing vessel, bal-
ance and the environment.
• Air turbulence due to open doors and windows, staff walking past the balance, air conditioning systems or
use of a safety cabinet, fume hood or glove box.
• The weighing vessel or the sample becoming electrostatically charged. These charges dissipate very slowly – often
taking several hours – from materials with low electrical conductivity, such as glass, plastics, powder or granulates.
• Vibrations from another instrument or device located close to the weighing bench, in adjoining rooms, or even
on floors above and below the laboratory.
• Volatile substances losing weight – for example due to the evaporation of water – or hygroscopic samples
gaining weight by absorption of atmospheric moisture.
• Samples with magnetic properties displaying a different weight depending on the orientation of the weighing pan.

These influences may result in balance readings drifting, much longer stabilization times, and weighing results
that are not reproducible. In addition, if a fault is identified with the balance itself, a repair may be necessary,
temporarily interrupting running procedures. Carefully controlling these external physical influences, reducing or
eliminating the effects as far as possible, enables faster, more stable and more accurate weighing. This consid-
erably improves the basic weighing steps involved in the workflow, making procedures far easier and less time
consuming to perform. In routine laboratory work, balances are frequently used by different people. To ensure
optimum performance, balances should be kept clean and free from dust or contaminants. This also protects
subsequent users from accidental exposure to – and contamination from – hazardous substances.

Figure 38: Cleaning of METTLER TOLEDO balances is easier

than ever before. The SmartPan and SmartGrid weighing
pans make sure that any spilled substances remain in the
tray underneath for safe disposal and cleaning. The com-
plete weighing chamber, weighing pans and draft shields
can be disassembled within seconds. All parts can be
cleaned efficiently in just a few seconds and all are dish-
washer safe. Smooth surfaces and rounded edges make
the whole balance easy to clean.

Learn more

E-Learning “External Influences and Cleaning”:

www.mt.com/lab-elearning-influences

This E-Learning course focuses on the six most common external influences that can seriously affect weigh-
ing results, and also offers solutions and tips to eliminate – or at least reduce – their effects. It also offers
guidelines for the proper location of a balance in the laboratory, as well as correct methods for cleaning.

Guide “8 Steps to a Clean Balance and 5 Solutions to Keep It Clean”:

www.mt.com/lab-cleaning-guide

This guide provides you a step-by-step guidance on how to clean a balance, a list of cleaning agents and their
suitability for different balance parts as well as many tips and tricks to avoid making your balance dirty at all.

28 Efficient Weighing Guide

METTLER TOLEDO
2.4 Fume Hoods, Glove Boxes and Safety Cabinets
Many substances are hazardous or volatile, and require careful handling within a safety cabinet, glove box or
fume hood. Unfortunately, this makes weighing an even more tedious and time-consuming task for a number
of reasons:
• It can be difficult to access and operate the balance.
• Opening the balance door can cause weighing instability due to air turbulence.
• Data handling is difficult; the use of a printer within a fume hood, safety cabinet or glove box is undesirable
due to the risk of the paper becoming soiled or even contaminated.

To help minimize weighing irregularities, dedicated draft shields with automatic, independently operating doors
can be used to protect the weighing pan and the tare container from the influence of drafts, along with grid
weighing pans that have been designed to have minimal surface area, reducing the impact of air turbulence. For
ease of use, optical sensors and footswitches provide touch-free operation, and the potential for soiling or con-
tamination of the balance printout is eliminated by electronic data recording or the use of Bluetooth® technology
to enable printing outside of the safety cabinet, fume hood or glove box. The combined effect is shorter settling
times and faster results.

Ultimately, the balance can work with its door closed under a laminar air flux with perfect stability and, with inte-
grated automatic anti-static kits, even handle statically-charged substances.

Figure 39: Working in a fume hood or safety cabinet can be tedious and time consuming. The innovative SmartPan weighing pan minimizes the
effects of air currents on the weighing cell – it can even allow working in a fume hood with a mg precision balance without a draft shield, making
weighing much easier and faster. A printer can be placed outside the fume hood and connected to the balance wirelessly.

Learn more
E-Learning “Safe Weighing Under Harsh Conditions”:
www.mt.com/lab-elearning-safeweighing

This E-Learning course explains the correct, safe use of balances in safety enclosures. It also aims to pro-
vide awareness of risk types when weighing toxic substances, choosing appropriate equipment for your
application, common hazards, safe weighing, and maintenance and routine testing.

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29
 2.5 User Ergonomics
Efficient Weighing
When working at a balance for a long period of time, ergonomics plays an important role. Users should ensure
that they adopt the correct sitting or standing position. When seated, the lumbar spine should be supported, and
a foot rest used if necessary. Users weighing from a standing position should try to avoid working with the neck
or back bent over the worktop or balance. To ensure that measurements can be read easily by all operators,
the balance should incorporate a large-digit display, and the brightness, contrast and display angle should be
adjustable. Dual-sided access to the weighing pan enables all users, whether left- or right-handed, to weigh with
ease, while optical sensors and footswitches provide hands-free operation of the balance. If heavy weights need
to be lifted, placing the balance on the floor or at knee height minimizes travelling distances. Simple steps, such
as using a chair instead of a stool, or mounting the balance display at eye level – either fixed to the wall or on
a terminal stand – can go a long way to increasing user comfort, productivity and health.

Figure 40: Correct posture and ergonomic, adjustable working places help to avoid health problems and injuries.

Learn more
Checklist to evaluate and optimize your laboratory ergonomics:
www.mt.com/labtec-ergonomics

This checklist contains 44 questions for self-evaluation of your laboratory workplace. It also includes many
useful tips and techniques to work safer and be more productive.

30 Efficient Weighing Guide

METTLER TOLEDO
3 Conclusions
This guide discusses how optimum efficiency and productivity can be achieved by carefully analyzing laboratory
procedures, identifying – and, as far as possible, eliminating – inefficiencies and introducing standardized pro-
cesses. For many typical chemistry workflows weighing is usually the first step, and the hints and tips discussed
in this guide – for example, weighing directly into tare containers – complemented by automation solutions, can
help to streamline procedures. This saves time – and consequently costs – while still maintaining the highest
possible product quality. The implementation of laboratory software incorporating user guidance ensures that
processes are performed correctly and data is accurately transferred for automatic secure storage.

4 Useful Links
Laboratory balances,
www.mt.com/balances
Quantos dosing solutions,
www.mt.com/quantos
LabX Laboratory Software,
www.mt.com/labx
GWP and routine testing,
www.mt.com/gwp
Moisture Analyzers:
www.mt.com/moisture
Lab Library:
www.mt.com/lab-library
Laboratory Expertise:
www.mt.com/lab-expertise
E-Learning courses,
www.mt.com/lab-elearning
Webinars, laboratory weighing:
www.mt.com/laboratoryweighing-webinars

Guide: Proper weighing with laboratory balances,

www.mt.com/lab-properweighing
Everything you need to know about electrostatic influences on weighing,
www.mt.com/lab-static
SmartPan weighing pans – minimizing the effects of air currents,
www.mt.com/smartpan
On-demand Webinar “The Importance of Data Integrity in a GXP Regulated Laboratory”,
www.mt.com/lab-data-webinar
White Paper “Drying Oven vs. Halogen Moisture Analyzer”:
www.mt.com/oven-vs-hma
Checklist: Lean lab – optimizing workplaces and workflows,
www.mt.com/lab-smart-weighing
Checklist: Evaluate and optimize laboratory ergonomics,
www.mt.com/labtec-ergonomics

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31
Accurate Measuring Through GWP®
The Global Weighing Standard
Good Weighing Practice™ (GWP®) is the science based global weighing
standard for the efficient life cycle management of weighing systems. The
risk-based approach allows you to improve control of your whole measuring
process, which in turn helps to avoid costly out of specification results.

Benchmark Your Quality

Management System
GWP® Verification helps you assure
accurate weighing results as part of
your quality management system.
Applicable for all balances and scales,
it provides an optimized testing and
calibrating scheme which may trans­late
to sustainable time and cost savings.

Your Benefits
• The accuracy of your weighing instruments is matched to your process tolerances.
• A comprehensive summary report provides an overview of the status of all
weighing equipment.
• An optimized routine testing and calibration schedule results in sustainable
cost savings.
• Audit-proof and up-to-date documentation complements your quality manage-
ment system.

For your success: you focus on your process, we take care of the measurement.
www.mt.com/gwp

www.mt.com
For more information

Mettler-Toledo International Inc.

CH-8606 Greifensee, Switzerland
Tel. +41 44 944 22 11
Fax +41 44 944 30 60

Subject to technical changes

© 11/2016 Mettler-Toledo GmbH
30366671
Global MarCom 2092 JS