With operational pressures mounting, manufacturers are turning to hands-on testing and real-world validation to make faster, smarter technology investments. Kiran Grewal reports.
In today’s manufacturing world, where margins are tight and operational complexity is rising, the stakes for capital investment have never been higher. Equipment decisions must go beyond specs on a brochure and reflect real-world performance, in real-world conditions. This is especially true in food safety, where undetected contaminants or false rejects can lead to costly recalls, reputational harm, and consumer safety risks.
One recent example highlights this need for robust contaminant detection. In April 2024, chocolate manufacturer Tony’s Chocolonely recalled several Easter products in the UK after small metal fragments were found in the packaging, a reminder that even quality-focused brands can face serious consequences from contamination issues. While the company acted responsibly and swiftly, the recall highlights why effective inspection technology is essential at every point in the supply chain.
Production line efficiency is under pressure, and manufacturers need to be confident that any new equipment investment will deliver value. That’s why Mettler-Toledo Product Inspection is spotlighting its Test Before You Invest programme – a global service designed to help food, pharmaceutical and packaging manufacturers make informed product inspection choices through hands-on testing, real performance data and expert support.
Rather than relying on theoretical specifications or off-the-shelf recommendations, the programme allows manufacturers to trial checkweighers, metal detectors, x-ray systems and vision inspection machines using their own product samples – before committing to a purchase. This gives businesses the opportunity to evaluate how product inspection equipment will perform in their specific application and production environment, removing guesswork and helping to avoid costly mistakes.
A global, flexible approach to testing
The Test Before You Invest programme is designed around how manufacturers prefer to trial and understand inspection equipment – providing multiple ways to explore and validate solutions, step by step.
It often begins with a visit from one of the Mettler-Toledo demo vans. Fully equipped with inspection technologies, these mobile showrooms allow manufacturers to see the systems up close at their own facility. Teams from operations, production, quality, procurement and management can all get hands-on time with the equipment, ask questions and begin evaluating the right fit for their line.
From there, many customers progress to testing their products at one of the Mettler-Toledo global Product Inspection Support Centres, located in the US, Spain, Malaysia and China. These centres allow manufacturers to send in product samples for detailed testing under controlled conditions. Line speed, product temperature, packaging type and other critical variables can be simulated to replicate real-world environments – helping determine how the inspection technology would perform under actual production demands.
Manufacturers can then participate in an eDemo which is an interactive remote session where Mettler-Toledo engineers demonstrate the testing process live via video link. These sessions include real-time insights, technical walkthroughs, and are followed up with a detailed sensitivity and performance report, enabling manufacturers to make evidence-based decisions from anywhere in the world.
For applications where validation in a live production environment is essential, manufacturers may then opt for the rental programme. This allows them to install a fully operational system on their own line for a set period, giving them full visibility of performance in real conditions – and complete confidence in their purchasing decision.
Detailed reports drive data-backed decisions
Each test concludes with a detailed, tailored report compiled by the Mettler-Toledo product inspection specialists. These reports provide valuable performance data such as achievable detection sensitivity, weighing accuracy, probability of detection and any production-specific factors that may influence system performance.
This objective insight helps manufacturers identify which technology – checkweighing, metal detection, x-ray or vision inspection – is most suitable for their needs. It also provides clear justification for internal stakeholders when making capital investment decisions. The ability to compare multiple system configurations or technologies side-by-side further supports smarter, faster decision-making.
Rather than making assumptions, manufacturers are empowered to invest based on real-world results that reflect their product, process and production line challenges.
Validating performance on-site with rental equipment
In many cases, manufacturers benefit from validating a system directly in their own facility. For these scenarios, Mettler-Toledo offers short-term rental equipment as part of the Test Before You Invest programme. This gives companies the opportunity to install a machine on their line temporarily and observe how it performs under actual production conditions.
Whether dealing with temperature-sensitive goods, varying pack sizes or specific contaminant detection challenges, on-site trials offer an extra layer of assurance. This is especially valuable when speed is critical – for example, during equipment failure, capacity constraints or when launching new product lines.
Rental machines are currently available across Europe and the US. Manufacturers in Asia and Australia are encouraged to contact their local Mettler-Toledo representative to explore testing and rental options tailored to their region.
Ongoing consultation and digital readiness
One of the standout features of the programme is the level of direct expert support it offers. After testing is complete, manufacturers can speak directly with Mettler-Toledo engineers to discuss the results in detail, ask questions about integration and explore additional tools that can support performance in the long term.
This includes solutions like ProdX™, the Mettler-Toledo data management software that enables real-time monitoring, centralised performance tracking and simplified compliance documentation across product inspection devices. For food manufacturers focused on digital transformation or audit readiness, integrating software like ProdX™ can help drive greater efficiency, accountability and visibility across the line.
With access to both physical testing and digital expertise, manufacturers get more than just a yes-or-no answer – they get a clear, informed pathway to operational improvement. Christine Gottschalk, Head of PI Test and Demo Center, Mettler-Toledo Garvens GmbH said, “As manufacturers face changing market demands, budget pressures and increasingly complex production environments, the Test Before You Invest programme provides a smart, low-risk route to better decision-making. Whether supporting urgent line upgrades, navigating approval delays or managing new product introductions, the programme helps manufacturers act with clarity and confidence.”
She continued: “By identifying the right inspection system up front – and validating it through practical testing – manufacturers can reduce disruption, improve throughput and maximise return on investment.”
Bridging the gap
In this environment of heightened quality expectations and economic pressure, it’s no surprise that digital transformation has become a top priority for manufacturers. Yet, the gap between intention and implementation remains wide.
According to new research from TraceGains, 82% of food and beverage brands say technology modernisation is a key business priority — but only 6% report being fully digital. The study, titled Digital Drag: The Growing Gap Between Tech Priorities and Implementation in the Food and Beverage Industry, found that despite growing concerns around compliance, agility, and operational resilience, many brands remain stalled by outdated systems and manual processes.
Despite nearly two-thirds (62%) expressing concern over economic uncertainty, in terms of tech preparedness to handle such disruption 60% remain stuck in implementation on the road to modernisation, with 69% continuing to rely on outdated manual processes citing complexity (40%) as a reason for the delay.
“The clock is ticking for food and beverage brands plagued by outdated ERP software and slow-moving consulting models that no longer serve the needs of today’s market,” said Paul Bradley, Senior Director of Product Marketing, TraceGains. “Our latest research confirms a shifting mindset from outdated playbooks to modern solutions capable of delivering impact right away and deployed in weeks, not months.”
Legacy systems handcuffs
The pressure to modernise is mounting for food and beverage (F&B) companies, yet many remain bogged down by legacy systems that hinder progress. These outdated workflows not only slow daily operations but also increase the risk of errors, regulatory non-compliance, and inefficiencies that stifle innovation. A striking 69% of F&B brands still depend on manual processes—such as paper documents, spreadsheets, fax, and email—for managing external work and document exchanges. More than half (55%) report that their operations are either not automated at all or only somewhat optimised. Alarmingly, just 6% have achieved fully integrated digital solutions, while 60% are stalled in the implementation phase. Furthermore, nearly one-third (29%) admit that their current operational management methods are inadequate and inefficient, leading to significant internal challenges.
Economic uncertainty shines a light on modernisation
Amid ongoing economic instability that continues to pressure margins and slow growth, F&B companies are grappling with the challenge of balancing urgent modernisation efforts with the need to mitigate near-term risks. When asked about their top concerns, 62% of F&B leaders pointed to broader economic uncertainty as their primary worry. Additionally, 23% cited difficulties in securing ingredients and materials, which directly impact innovation and the development of new products. Compliance and regulatory pressures are also top of mind, with nearly a quarter (24%) stating they would expedite the purchase of new technology within 90 days if necessary to meet a mandate. Despite these concerns, a strong majority—82%—still rank the implementation of new technology as a top business priority, surpassing other strategic initiatives.
What brands want: Ease of use, speed and simplicity
Operational ease has become a critical differentiator for F&B brands, with many prioritizing the ability to improve daily operations and deploy solutions quickly over long-term strategic planning. In fact, 57% of decision-makers identified improved process efficiency and the ease and speed of implementation as the primary drivers behind their technology adoption choices. More than half (52%) said they would be most inclined to invest in new technology if it delivered immediate operational improvements—surpassing considerations like return on investment (34%) and overall cost (22%). Additionally, 60% reported they would be significantly or somewhat more likely to adopt a solution if it could be implemented in weeks rather than months. However, for 40% of respondents, the biggest barrier to adopting new tools was the perceived complexity and implementation challenges, which outweighed even financial concerns.
Manufacturers can no longer afford to gamble on guesswork. Programmes like Test Before You Invest reflect a broader shift toward smarter, data-driven decision-making, which are empowering companies to modernise with confidence and clarity.
