Piece counting - Mettler Toledo

Piece counting 

What really counts 

in your processes?


2 

How can you find the right piece counting 

scales for your needs? 

Did you know that even pieces that appear to be identical may have different weights? Different weight is caused 

by production tolerances, material stock, tooling machines and operators. The average piece weight must there- 

fore be determined with extreme accuracy using a suitable, precise scale. A small error in this value is multiplied 

when counting bulk volumes. The following procedure will help you make the right selection. 

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2 

3 

4 

5 

Determine the average single piece weight: 

First you must determine the mean value of the single piece weight. To do this, individually weigh 10 pieces of the 

parts to be counted and enter each of the individual piece weights into their own cell in MS Excel ® . Calculate the 

average weight by adding all 10 weights and then dividing by 10. Using Excel‘s function for standard deviation, 

you can then calculate the absolute standard deviation in grams and the relative standard deviation as a percentage. 

Define the maximum weighing range of your piece counting scales: 

Weigh the heaviest pieces to be counted. Multiply this weight by the maximum number of pieces to be counted in 

the same process. This will give you the maximum net weight. The maximum gross weight is the sum of the 

maximum net weight and the weight of the heaviest tare container. It may not exceed the weighing range of the scale. 

Now find the right piece counting scales: 

Using the information on the weighing range, the smallest piece weight and its standard deviation, you can now 

find the right piece counting scale or the right two-scale system in the overview on the following page. 

Select the performance level of the display, keyboard and software: 

• If you require completely simple yet professional operation using one function for each key, then select an 

IND435 terminal or one of the compact scales BBA432 or BBK432. 

• If you want to easily and safely count many identical portions, then select an IND445/IND449check+ or 

a BBA442/BBA449check+/BBK442. You also can enter the tare value using the numeric keyboard. 

• Compact scales BBA462, BBK462 as well as IND465/IND449check+ and IND690count also include a 

graphic and plain text display for easy administration of up to 1500 memory locations 

(IND690count: 999 memory locations). They support printing of different labels or customized labels. 

• The IND690count terminal provides easy operability and first-class functionality. The large and bright 

BigWeight ® graphic display guides the user correctly through the counting process. 

Details on the displays, keyboards and interfaces can be found on pages 4–5. 

Select the right-sized model: 

• The BBK4x2 and BBA4x2 models are space-saving compact scales. 

• If you would like the display to be at the side, in front of or over the piece container, then select one of 

the IND terminals. 

• Determine the size and model of the floor scale. Decide whether to install the weighing platform in a pit 

or if it is to be directly fixed to the floor. 

• Select a Series 4 model if you wish to operate the scale with batteries and/or as a mobile unit, e.g. on a cart. 

Possible models and their details are given on pages 6–7.

Weighing 

range 

6000 lb 

3000 kg 

2500 lb 

1250 kg 

1000 lb 

500 kg 

600 lb 

300 kg 

300 lb 

150 kg 

120 lb 

60 kg 

70 lb 

35 kg 

30 lb 

15 kg 

12 lb 

6 kg 

6 lb 

3 kg 

1.2 lb 

0.6 kg 

0.6 lb 

0.3 kg 

0.2 lb 

0.1 kg 

IND690 + 

AB304-S 

IND4x5 + 

AB304-S 

IND690 + 

AB104-S 

IND4x5 + 

AB104-S 

IND690+ 

X603S 

+KA32s 

BBK4x2-0.6Px 

X603S 

IND690 + 

X203S 

IND4x5 + 

X203S 

IND690 + 

BBK4x2-3Px 

+ KCC300S 

IND690 + 

BBK4x2-3Px 

+ KB60s 

IND690 + 

BBK4x2-3Px 

+ KA32s 

BBK4x2-3Px 

IND690 + 

BBK4x2-6Px 

+ KCC600s 

IND690 + 

BBK4x2-6Px 

+ KCC300s 

BBK4x2-6Px 

+ 

PBA330-60BB 

IND690 + 

KA32s 

BBK4x2-35Sx 

BBK4x2-6Px 

IND690 

PBA330-6A 

+ KE1500s 

IND690/ 

PBA330-6A 

+ 2256 VLC 

BBK4x2-6Px 

+ 

PBA330- 

150CC 

IND690 + 

KA32s 

BBK4x2-35sx 

BBA4x2-6Px 

IND690/ 

IND4x5+ 

PBA330-35BB 

+ 

2158 Vertex 

IND690/ 

IND4x5+ 

PBA330-35BB 

+ 

2158 Vertex 

IND690/ 

IND4x5+ 

PBA330-35BB 

+ 

2256 VLC 

IND4x5 + 

PBA330- 

300BC 

BBA4x2-35Sx 

0.0000002 lb 0.000002 lb 0.00002 lb 0.0002 lb 0.002 lb 0.02 lb 

Average Piece Weight 1) 

0.000002 lb 0.00002 lb 0.0002 lb 0.002 lb 0.02 lb 0.2 lb 

Average Piece Weight 2) 

Counting terminals 

– IND690count 

– IND465 

– IND445 

– IND435 

Reference scales 

– X203S 

– X603S 

– AB104-S 

– AB304-S 

Series 4 compact scales 

– BBK4x2-3Px 

– BBK4x2-6Px 

– BBK4x2-35Sx 

– BBA4x2-6Px 

– BBA4x2-35Sx 

Weighing platforms 

– KA32s 

– PBA330-BB35 

– PBA330-BB60 

– PBA330-6A 

– KE3000 

– KES3000 

– KCS600 

– 2158 Vertex Rocker Pin 

– 2256 VLC Floor Scale Footed 

1) Counts up to 1000 pieces in normal 

ambient conditions at a relative standard 

deviation of < 0.5% of the average 

piece weight. 

Standard Deviation is calculated as 

described under point 1 on page 2. 

2) Counts up to 1000 pieces in normal 

ambient conditions at a relative standard 

deviation of 0.5–1% of the average 

piece weight. 

Standard Deviation is calculated as 

described under point 1 on page 2. 

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4 

The right solution for every job 

IND690count: the robust and intelligent counting system 

• The robust and versatile IND690count stainless steel terminal is IP69k-protected and is therefore also suitable 

for use in the harshest industrial environments – with a matching, robust industrial GA46 printer contained 

in stainless steel housing for printing barcodes. 

• The large, bright, high-contrast ”BigWeight ® “ display allows counting results to be easily read without tiring 

your eyes – even at large distances and in poorly lit conditions. 

• Up to four weighing platforms can be connected, this allows high-resolution, precise weighing ranges of 

0.1 mg to 6000 kg/0.0000002 lb to 12,000 lb using just one IND690count terminal. 

• The integrated database provides 999 flexible storage locations for part data. 

• The IND690count terminal can be connected to a warehouse management system via Ethernet TCP/IP, Profibus DP, 

DeviceNet, USB, Bluetooth, WLAN, RS232, RS422, RS485, digital inputs/outputs and RFID, making it the central 

tool for registering incoming/outgoing goods and for inventory management. 

Intelligent commissioning and portioning using BBK462, BBA462 and IND465 

• The bright graphic display avoids misunderstandings, as it guides the user through the counting process using 

plain text instructions. 

• An integrated database with 1,500 flexible storage locations allows part data to be managed easily. 

• Barcode scanners are used to ensure error-free, efficient part selection. 

• Monotonous work, such as filling many identical packaging units, can be done efficiently. The filling guide informs 

the user when the target has been reached. Underfilling or overfilling is therefore avoided. 

• Free design of barcode print-outs on labels, e.g., with name of company, address, alphanumerical part ID, date, 

time, variables, lot ID and order number. 

• Can be integrated into existing systems using Ethernet TCP/IP and digital inputs/outputs. 

• A second scale can be connected for larger volumes or for exact piece weight sampling. 

Correct Order filling using BBK442, BBA442, IND445, BBA449check+, IND449check+ 

• Tedious work, such as filling many identical packaging units, is simplified, as the filling guide informs the user 

when the target has been reached. The BBA449check+ has the colorWeight ® function. It supports the operator 

with a color change of the display if the target weight is reached. Underfilling or overfilling is therefore avoided. 

• Comes with a database of 99 flexible storage locations for target counts with tolerances and tare values. 

• Flexible print-outs with name of company, address, and numerical part ID. The part ID can be entered using the scale 

keyboard or a barcode reader. 

• A second scale can be connected for large volumes or for exact piece weight sampling to BBK442, BBA442 and IND445. 

• The tare values can be entered on the keyboard. 

Simple, safe and professional: BBK432, BBA432, IND435 

• Secure entry due to allocation of one single function to each key minimizes operator error. 

• Keys and display have been optimized simply and without compromise for counting. 

• Password-protected settings. 

• A second scale can be connected for large volumes or for exact piece weight sampling.

METTLER TOLEDO 




USB 

EtherNet 

DeviceNet 

RS232 

MonoBloc provides the highest rate of counting 

precision and repeatability – for reliable results. 

The BBK4x2 scales and K-Line weighing platforms 

are equipped with unique MonoBloc technology 

for maximum repeatability and precision of weighing 

and counting results. 

Their high measuring resolution allows for a high 

weighing range at a very high rate of precision, 

linearity and repeatability. Generally, this means: 

MonoBloc is 10–20 times more accurate than 

strain gauge technology. 

RefOpt: User-friendly, precise determination 

of piece weights 

Using the “automatic reference optimization“ function, 

you can count easily, efficiently and correctly. 

The scale continuously optimizes the piece weight. 

Interfaces 

Depending on the model, the METTLER TOLEDO 

counting systems and counting scales can be 

integrated into a modern materials management 

system. With Ethernet TCP/IP, Profibus DP, USB, 

Bluetooth, DeviceNet and RFID, all types of connection 

are covered and all data can flow freely. 

WLAN R F I D 

Battery powered 

Selected models also available with optional rechargeable 

battery for mobile use. 

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The right models and sizes for 

your application 

Combine small, medium and large platforms with modular compact scales and the powerful IND counting 

terminals. Position the terminal in the ideal location for your needs: to the side, the front or on a mount. 

Connect the compact BBK and BBA models to bench and floor scales to form two-scale systems. 

Compact Scales Small Sizes 

NTEP-approved BBA4x2: Class III, 7,500d 

BBK4x2: Class II, 60,000d 

Housing Die-cast aluminum 

Measuring method BBK4x2 MonoBloc/BBA4x2 Strain Gauge 

Power supply 110V AC or built-in rechargeable battery 

Dimensions (in/mm) 10.40 × 13.20 × 4/265 × 335 × 100 

Platform size (in/mm) 6.50 × 6.50/165 × 165 1 


Interfaces Ethernet TCP/IP, USB, digital I/O, 

up to 3× RS232, RS485, connection for 

second scale (depending on application level) 

Model Weighing range Resolution Platform 

size 

BBK432-3PL 6 lb × 0.00002 lb 3 kg × 0.01g 1 

BBK442-3PD 6 lb × 0.00002 lb 3 kg × 0.01g 1 

BBK462-3PT 6 lb × 0.00002 lb 3 kg × 0.01g 1 

BBK432-6PL 12 lb × 0.00005 lb 6 kg × 0.02g 2 

BBK442-6PD 12 lb × 0.00005 lb 6 kg × 0.02g 2 

BBK462-6PT 12 lb × 0.00005 lb 6 kg × 0.02g 2 

BBA432-3PL 6 lb × 0.0005 lb 3 kg × 0.2g 2 

BBA442-3PD 6 lb × 0.0005 lb 3 kg × 0.2g 2 

BBA462-3PT 6 lb × 0.0005 lb 3 kg × 0.2g 2 

BBA432-6PL 12 lb × 0.00005 lb 6 kg × 0.5g 2 

BBA442-6PD 12 lb × 0.00005 lb 6 kg × 0.5g 2 

BBA462-6PT 12 lb × 0.00005 lb 6 kg × 0.5g 2 

AB Balances 

Reference balances for small parts 

Model Weighing range Resolution 

AB104-S 110 g 0.0001 g 

AB304-S 320 g 0.0001 g 

Platform size (in/mm) Ø 3.15/80 

Compact Scales Large Sizes 

NTEP-approved BBA4x2: Class III, 7,500d 

BBK4x2: Class II, 60,000d 

Housing Die-cast aluminum 

Measuring method BBK4x2 MonoBloc/BBA4x2 Strain Gauge 


Dimensions (in/mm) 14.17 × 14.56 × 4.53/360 × 370 × 115 


Interfaces thernet TCP/IP, USB, digital I/O, 

up to 3 × RS232, RS485, connection for 

second scale (depending on application level) 

Model Weighing range Resolution Platform 

size 

BBK432-15SL 30 lb × 0.0001lb 15 kg × 0.05 g 3 

BBK442-15SD 30 lb × 0.0001lb 15 kg × 0.05 g 3 

BBK462-15ST 30 lb × 0.0001lb 15 kg × 0.05 g 3 

BBK432-35SL 70 lb × 0.0001lb 35 kg × 0.1g 3 

BBK442-35SD 70 lb × 0.0001lb 35 kg × 0.1g 3 

BBK462-35ST 70 lb × 0.0001lb 35 kg × 0.1g 3 

BBA432-15SL 30 lb × 0.002 lb 15 kg × 1g 3 

BBA442-15SD 30 lb × 0.002 lb 15 kg × 1g 3 

BBA462-15ST 30 lb × 0.002 lb 15 kg × 1g 3 

BBA432-35SL 70 lb × 0.005 lb 35 kg × 2g 3 

BBA442-35SD 70 lb × 0.005 lb 35 kg × 2g 3 

BBA462-35ST 70 lb × 0.005 lb 35 kg × 2g 3 

BBA432-60SL 120 lb × 0.01lb 60 kg × 5g 3 

BBA442-60SD 120 lb × 0.01lb 60 kg × 5g 3 

BBA462-60ST 120 lb × 0.01lb 60 kg × 5g 3 

X203S/X603S Balances 

Reference balances for small parts 

Model Weighing range Resolution 

X203S 210 g 0.001 g 

X603S 610 g 0.001 g 

Platform size (in/mm) 5 × 5/127 ×127

K Line High Precision 

High-precision bench and floor scales for use in harsh industrial 

environments. Can be used as reference scales or bulk scales. 

NTEP-approved Class III 10,000d 

Class II 32,000d 

Weighing ranges 6–6,000 lb/3–3,000 kg 

Resolution 0.00002–0.1lb/0.01–50 g 

Platform sizes 13.8 × 11 to 59 × 59 in 

2158 Vertex Rocker Pin Floor Scale 

Carbon steel painted or stainless steel floor scales for use as 

bulk scales in harsh industrial environments. 


Weighing ranges 1,000–20,000 lb 

Resolution 5,000d, 10,000d (option, non-approved) 

Platform sizes 3 × 3 to 5 × 7 ft or custom dimensions 

2256 VLC Floor Scales 

Floor scales for use in harsh industrial environments. 


Weighing ranges 1,000–10,000 lb/450–4,500 kg 

Resolution 0.2–2 lb/0.1–1kg 

Platform sizes 3 × 3 to 5 × 7 ft 

PBA330 and CBUx Bench Scales 

Scales that can be used as bench, stand, and floor-mounted 

for use as bulk scales. 

NTEP-approved PBA330 class III 5,000d 

CBUx class III 10,000d 

Weighing ranges 12–1,200 lb/6–600 kg 

Resolution 0.002 to 0.2 lb/1–200 g 

Platform sizes 9 × 9 to 24 × 32 in 

240 × 240 to 600 × 800 mm 

IND4x5 Weighing Terminal 

NTEP-approved class III 10,000d for strain gauge cells 

class II 100,000d with approved balance 

Housing Die cast aluminum 

Protection IP65 

Measuring method Strain gauge 


Connection Can connect up to 2 scales 

Optional Interfaces Ethernet TCP/IP, USB, digital I/O, 

RS232, RS485 

IND449check+ Weighing Terminal 


class II 100,000 with approved balance 

Housing Stainless steel 

Protection IP69k 



Optional Interfaces Ethernet TCP/IP, USB, digital I/O, RS232, RS485 

BBA449check+ Compact Scale 


Housing Stainless Steel 




Platform size A 9,4 × 11.8 in 

Platform size QA 9 × 9 in 

Platform size B 15.7 × 19.7 in 

Platform size QB 12 × 12 in 

Platform size BB 11.8 × 15.7 in 

Model Weighing range Resolution Pf. size (in) 

BBA449 003Z 6 lb × 0.001lb 3 kg × 0.0005 g A 

BBA449 006Z 12 lb × 0.002 lb 6 kg × 0.001g A, QA 

BBA449 015Z 15 lb × 0.002 lb 6 kg × 0.001g A, QB 

BBA449 030Z 30 lb × 0.005 lb 15 kg × 0.002 g BB, QB, B 

BBA449 060Z 60 lb × 0.01 lb 30 kg × 0.005 g BB, QB, B 

BBA449 150Z 150 lb × 0.02 lb 60 kg × 0.01g B 

Optional Interfaces Ethernet TCP/IP, USB, 

WLAN, digital I/O, RS232, RS485 

IND690count Weighing Terminal 


class II 100,000d for K-Line, BBK, AB, X 

Housing Stainless steel 


Measuring method MonoBloc and strain gauge 

Connection Can connect up to 4 scales 

Optional Interfaces Ethernet TCP/IP, Profibus DP, DeviceNet, 

WLAN, Bluetooth, USB, RFID, digital I/O, RS232, 

Current Loop, RS485/422, analog output 

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Reliable numbers for incoming goods 

facilitate seamless production 

Precise weighing and counting 

from 1 mg to 6000 kg 

METTLER TOLEDO has a range of 

scales that cover all counting and 

weighing requirements for incoming 

goods. The incoming goods area 

of a company is often very hectic. 

Depending on the situation, many 

deliveries are often accepted and 

checked at the same time. Packages 

have different sizes, ranging from 

containers, through pallets, right 

down to smaller packages and even 

letters with small consignments. 

The weighing technology used for 

incoming goods must therefore cover 

a wide range from 0.000002 to 

12,000 lb. In certain circumstances, 

as many as 10,000 pieces must be 

counted within one package. Precise 

weighing down to the last and even 

lightest piece requires a precision 

bench scale. Counting pieces that are 

delivered on pallets or in bulk containers 

require high capacity scales. 

BigWeight ® display – 

never get fatigued 

The bright, high-contrast graphic 

display of the IND690count, 

provides the user with legible in- 

structions and information. The patented 

BigWeight ® function is unique. 

It allows you to avoid reading errors 

and premature fatigue. The keys, 

which are uniquely labeled for piece 

counting, enable efficient work 

and help prevent operator errors. 

Robust industrial equipment 

In the shipping and receiving area, 

awkward and heavy packages 

are transported manually, with a 

fork-lift truck, a hand-truck 

or even a crane. METTLER TOLEDO 

scales withstand these condi- 

tions due to their high overload 

protection. Their terminals are 

protected up to IP69k and continue 

to work reliably even in dusty 

or damp environments.

Several printers connectable 

Several label printers can be connected 

to the IND690. This increases 

efficiency if you need several label 

sizes. The layout and configuration of 

the label size can be stored directly 

on the printer. You don’t need an 

additional IT system just for printing. 

Always the correct scale, with 

multiple connection capabilities 

Always count and weigh on the right 

scale and at the right place. 

Up to four scales can be connected to 

an IND690count terminal. 

Network capable 

The data recorded via the barcode 

readers, keyboards or RFID 

readers can be transferred to an 

IND690count terminal via RS232, 

USB or Bluetooth. The data is then 

transferred via Ethernet TCP/IP or 

Profibus to the ERP system or the 

PLC. The IND690count terminal then 

assumes the function of a local 

network node with user guidance. 

Greater efficiency with a database 

The IND690count has a database with 999 storage 

locations for the part ID, piece weight, tare weight 

and target weight with tolerances. The stored values 

can be called up by barcode reader or keyboard. 

The database can be easily edited and stored 

on the computer using the “COUNT Tool“ software 

and loaded onto the IND690count. 

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10 

Every piece is important – 

in the warehouse, when taking inventory, 

order filling and shipping goods 

User-friendly order filling 

with colorWeight ® 

Even if there is a large number of 

bags, order filling remains easy 

and efficient. The BBA449check+ 

supports the operator with the 

colorWeight ® function in target 

weighing. The back-lit display of 

this counting scale can change its 

color from light blue to green, 

yellow or red. The limits for the color 

change can be set with the key 

board. It can change to one of the 

three colors after the preset number 

of parts is reached. The customer 

can determine which color he wants 

to allocate to which status. 

The scale can also signal the filling 

status to a machine with digital I/O. 

Target count not reached. 

Still far away from target. 

Target count not reached. 

Close to target. 

Target count reached, OK. 

Overfill. 

Target count exceeded.

Network capable 

Data recorded using barcode readers 

or keyboards can be transferred to 

the scale. The data is transferred via 

Ethernet TCP/IP to a computer or 

the ERP system. The compact scales 

BBA4x2, BBK4x2 or the IND4x5 

terminal assume the role of local network 

nodes. 

Greater efficiency with a database 

The IND465, BBA462 and BBK462 

models have a database with 

1500 storage locations. The storage 

locations offer enough space for 

the part ID, piece weight, tare weight 

and target weight with tolerances. 

The stored values can be called up 

by barcode reader or keyboard. 

The database can be easily edited, 

managed and stored on the computer 

using the “Smart Manager” 

program. It can also be used to 

download data to the scale. 

The “Smart Manager” even allows 

import/export of data files for 

use with MS Excel ® . 

Printers 

Select your ideal solution from 

a multitude of various label, 

strip and ticket printers. The print 

possibilities vary depending 

on the built-in application. 

Mobile counting in the order picking warehouse 

As it can be powered by battery, the scale can 

be operated on a cart. Compact scales BBK462 

and BBA462 have 1500 storage locations for 

target weight, tolerance, identification, piece weight 

and tare weight. Barcode readers, a keyboard or 

printer can be also connected. This keeps the scale 

mobile throughout the day and allows it to be 

used independently in the order picking warehouse. 

11

High-resolution 

two-scale system 

Piece weights vary from piece to piece. It depends on the machine, the day or the 

operator who has produced the parts. A small error when determining the average 

piece weight is multiplied when counting larger quantities. Therefore, when there 

is a large variation, the average piece weight must be determined using a greater 

number of reference pieces. You also require a high-resolution and high-precision 

reference scale. 

For very small parts, the AB104-S and AB304-S platforms are used. The AB104-S and 

AB304-S can be connected as reference scales or stand-alone scales to the IN690count, 

IND465, IND445, IND435 and IND449check+ counting terminals. They act as pure 

reference scales together with compact scale models BBK432, BBK442 and BBK465. 

This allows you to use all the features that make the METTLER TOLEDO scales so userfriendly 

and efficient with the highest resolution and precision. 

USA 

Mettler-Toledo, Inc. 

1900 Polaris Parkway 

Columbus, OH, 43240 

Tel. (1) 800 523 5123 

Subject to technical changes 

© 0x/2008 Mettler-Toledo AG 

Printed in Switzerland 

MTSI XXXXXXX 

Canada 

Mettler-Toledo, Inc. 

2915 Argentia Road, Unit 6 

Mississauga, Ontario, L5N 8G6 

Tel. (1) 800 523 5123 

www.mt.com/counting 

Mettler-Toledo AG 

Sales International 

CH-8606 Greifensee 

Switzerland 

Tel. + 41 44 944 22 11 

For more information

Piece counting - Mettler Toledo

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