Choosing the right weighing machine is a critical decision for a variety of businesses operating in the food, packaging and FMCG industries. Weighing isn't just about putting products in to bags, it greatly impacts the accuracy, speed, productivity, waste reduction and ultimately profitability. Two popular solutions in automated production lines are the Multihead Weigher and the Linear Weigher.
It can be hard for a business to choose the right solution for their needs. Especially when they don't have much knowledge about the different machines within a packing line. This comprehensive guide will help you understand what sets these two solutions apart and which option might be better for your business.
In this guide, we'll break down:
- How each machine operates
- Key performance differences
- Real-world use cases
- Cost and ROI considerations
- Examples of Scayl's Multihead and Linear Weighers
- How to choose the best solution for your operation
By the end you'll have all the information to make confident and informed decisions on which solution will suit your business best.
How Does a Multihead Weigher Work?
A Multihead Weigher, also known as a combination weigher, is designed for high-speed, high-accuracy weighing. Unlike linear systems, Multihead weighers use multiple weigh hoppers - typically ranging from 10 to 24 (sometimes more) - to calculate the optimal combination of product portions to reach a target weight.
Step-by-step process:
- Bulk product enters a central feed cone.
- Vibratory feeders distribute product evenly into multiple weigh hoppers.
- Each hopper continuously weighs its portion of the product.
- Advanced software calculates the best combination of hoppers to hit the exact target weight.
- Selected hoppers discharge simultaneously into the packaging system.
This combination weighing approach allows Multihead Weighers to operate at high speeds while maintaining great accuracy. They are ideal for fragile products like crisps or confectionary, as well as mixed or irregular items such as trail mix, frozen vegetables, or even ready meals!
Scayl Multihead Examples:
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Multi‑1425: 14 heads, 2.5L hoppers, ±0.1–2g accuracy, speeds up to 70 PPM, ideal for snacks and confectionery.
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Multi‑1450: 14 heads, 5L hoppers, high-throughput, suitable for frozen foods, ready meals, and pet food lines.
💡 Tip: If you’re unsure which Multihead model fits your production, Scayl’s team can advise based on your industry, product type, and speed requirements.
How Does a Linear Weigher Work?
A Linear Weigher is much simpler than a Multihead, it uses vibrating pans arranged in a straight line to feed the product directly into weigh hoppers. Unlike Multiheads, Linear Weighing machines weigh product directly without combination calculations.
Step-by-step process:
- Product moves long the vibrating pans
- Material flows into one or more weigh hoppers (this can be done by hand or with a Vacuum Loader)
- Hopper weighs the product to set amount
- Once the target weight is reached, the hopper discharges the product into packaging.
Linear Weighers are perfect for uniform, free-flowing products like coffee, tea, grains, nuts or even pellets, ideal for a variety of businesses that need simplicity and low-maintenance machines.
Bespoke Linear Weighers for Businesses.
At Scayl, our Linear Weighers can be customised to suit specific product or hygiene requirements:
- Dimpled Steel can be added to the weighers to reduce sticking for sticky or oily products
- Teflon-coated pans and hoppers for products that require non-stick, easy-clean surfaces.
- 304 stainless steel for hygiene-sensitive applications such as food, pharmaceuticals, or nutraceuticals
These bespoke add-ons allow businesses to optimise cleaning efficiency, product flow and durability, making Linear Weighers versatile across many industries.
Scayl Linear Weigher Examples:
- Lin 280: Dual-head, 8L hoppers, 100g–5kg. Ideal for bakery and snack operations.
- Lin 2200: Dual-head, 1–10kg. Suitable for industrial and frozen food lines.
- Lin 1500G: Single-head gravity-fed, 5–25kg. Perfect for bulk industrial products.
- Lin 350A / 450A: Auger-fed models, handling sticky or challenging products such as pet food or confectionery.
💡 Tip: Not sure which linear model or bespoke configuration works for your product? Scayl’s team can assess your production needs and recommend the best solution for your business, including custom coatings, materials, and finishes.
Key Performance Differences
| Feature | Multihead Weigher | Linear Weigher |
|---|---|---|
| Accuracy | ±0.1g or better | ±1–3%, suitable for simple products |
| Speed | 60–120+ packs/min | Lower PPM depending on head count |
| Product Handling | Delicate, mixed, irregular | Uniform, free-flowing |
| Maintenance | Skilled operation, regular calibration | Simple, easy maintenance |
| Packaging Integration | VFFS, HFFS, tray packers, MAP, vacuum, thermoforming | VFFS, small pouch machines |
Real-World Use Cases Across Industries
Multihead and Linear Weighers are used across a wide range of different industries, not just food. Here are some examples:
Multihead Weigher Use Cases
- Snack & Confectionery: Crisps, popcorn, chocolate, trail mix, high speed and gentle handling prevent breakage.
- Frozen Foods: IQF vegetables, ready meals, accurate portioning maintains consistency.
- Fresh Produce & Meat: Pre-portioned vegetables, poultry, or seafood for retail or ready meals.
- Pet Food & Animal Feed: Mixed dry kibble or premium treats, multi-component mixing ensures consistency.
- Pharmaceuticals & Nutraceuticals: Capsules, powders, and granules requiring precise dosing.
Linear Weigher Use Cases
- Bakery & Dry Goods: Flour, sugar, nuts, grains, uniform flow and moderate speed.
- Industrial Materials: Fertilisers, small parts, chemical granules, bulk weighing simplicity.
- Small to Medium Food Lines: Snack bars, sweets, nuts, lower volume, cost-effective operation.
- Pet Food: Simple kibble lines where high-speed combination weighing isn’t required.
Cost and ROI Considerations
Linear Weighers:
- Lower upfront cost and simple maintenance
- Good for smaller production lines or smaller businesses with limited budgets.
Multihead Weighers:
- Higher initial investment
- Long term savings due to reduced spillage, faster output and consistent quality, providing excellent long-term ROI.
How to Choose the Best Solution for Your Operation?
When it comes to selecting the right weighing system it's more than just choosing between a Multihead Weigher or a Linear Weigher. It requires a clear understanding of your product characteristics, production goals, packaging and also long-term growth plans. Making the right decision at this stage is critical for improving efficiency, reduce waste and spillage and increase profitability.
below are key factors that you should consider when choosing the best solution for your business.
1. Consider Production Volume
Your output speed will strongly influence which weighing system is most suitable.
- High speed and high volume production = Multihead Weigher
Multihead Weighers are capable of producing dozens or even hundreds of packs per minute, making them ideal for large scale operations, contract packers and growing businesses that are looking to scale.
- Small to medium output = Linear Weigher
For businesses with lower throughput requirements, linear weighers provide reliable performance without the added complexity or investment of a multihead system.
If you're unsure on which solution is most suitable Scayl provides free production consultations to calculate realistic throughput targets and to ensure that your weighing system aligns with your packaging line speed and also your future growth plans.
2. Evaluate Accuracy Requirements
Accuracy is critical not only for profitability, but also for legal compliance, particularly for products sold under the ℮ (e-mark) system.
The ℮ symbol indicates that a product complies with the Average Quantity System, a legal framework used in the UK and EU. It allows small variations in individual pack weights, provided:
- The average pack weight meets or exceeds the declared weight
- Only a limited number of packs fall below the target
- No pack exceeds the tolerable negative error (TNE)
To remain compliant, weighing machines must be accurate, consistent, and correctly calibrated.
Can Linear and Multihead Weighers Handle Tight Tolerances?
Yes, both linear and multihead weighers can achieve tight tolerances, depending on:
- Product weight
- Product volume
- Flow characteristics
- Machine configuration and calibration
All Scayl linear and multihead weighers are engineered to deliver high accuracy, typically within:
±0.1–1g to ±2g, depending on the application.
3. Factor in Budget and Maintenance
Initial investment and long-term ownership costs should be carefully considering, as scaling up and investing in new machinery can be a big step for a business of any size. Scayl's team offer fantastic support for businesses looking at scaling up their production, with a friendly team that can help look at finance options, payment plans and picking a suitable machine for your budget. Get in touch today to help you pick the right solution for your business needs.
4. Check Packaging Integration needs
Your weighing system must integrate seamlessly with your existing or planned packaging machinery to ensure smooth operation, consistent output, and minimal downtime. Compatibility between the weigher and the rest of the line is essential for maintaining efficiency and scalability.
Advanced Automation & Multiple Product Types
Multihead Weigher: Multihead weighers are highly adaptable and are commonly integrated into fully automated packaging lines. They work seamlessly with a wide range of packaging systems, including:
- Vertical Form Fill Seal (VFFS) machines
- Horizontal Form Fill Seal (HFFS) machines
- Tray packing systems
- Modified Atmosphere Packaging (MAP) machines
- Vacuum packaging machines
- Thermoforming packaging machines
This makes multihead weighers ideal for operations handling multiple product types, frequent changeovers, or high-speed production environments.
Simple Packaging Lines & Cost-Efficient Setups
Linear Weigher: Linear weighers are well suited to simpler packaging configurations, particularly:
- Basic pouch machines
- Entry-level or mid-range VFFS lines
- Low-to-medium throughput operations
Their straightforward integration and compact design make them a cost-effective solution where efficiency, reliability, and ease of operation are key priorities.
Bespoke Integration Solutions from Scayl
Regardless of whether you choose a linear or multihead weigher, all Scayl machines can be paired with bespoke packaging solutions to suit your exact production requirements.
Scayl can supply and integrate:
- VFFS packaging machines
- Custom working platforms and frames
- Conveyors and infeed systems
- Discharge chutes and bespoke interfaces
- Full turnkey weighing and packaging solutions
Whether you’re upgrading an existing line or designing a brand-new packaging system, Scayl ensures that your weighing equipment integrates perfectly with your workflow, factory layout, and automation goals.
