The product can change before it reaches the metering chamber
Pumping, recirculation, high-speed mixing and repeated handling can change apparent viscosity or introduce air. A filler trial should use product delivered in the same way planned for production, including realistic hose lengths, pump settings and waiting time.
Temperature drift also changes flow and cut-off. Define the minimum and maximum normal product condition and check dose, texture, air pockets and nozzle behaviour at both limits.
Emulsion stability
Confirm the selected pump and filling route do not create unacceptable separation or texture change.
Entrained air
Assess bubbles, density variation and dose repeatability after normal transfer.
Stringing
Use a suitable shut-off and fill profile to protect jar necks and pot rims.
Hygienic boundary
Define product exposure, cleaning, strip-down and verification with appropriate technical expertise.
Choose the pack before finalising the filling machine
Container opening, stability, closure, sealing surface and decoration determine how the product can be presented, filled and transferred. Use commercial samples from the intended supplier and include dimensional variation in the trial.
| Pack route | Application considerations |
|---|---|
| Glass or plastic jars | Provide a wide opening and stable presentation; clean finishes are essential for cap or foil performance. |
| Squeeze bottles | Need controlled neck entry, bottle support and clean cap application. |
| Pots and tubs | Require consistent denesting or indexing and an uncontaminated sealing flange. |
| Pre-made pouches | Need reliable opening, support, controlled filling and seal-zone protection. |
Build the machine route from product feed to finished pack
Low-shear feed
Select pumps, speeds and pipework that preserve the agreed product condition.
Stable hopper management
Avoid unnecessary recirculation, long dwell or refill methods that trap air.
Positive cut-off
Prove clean nozzle closure at both temperature and viscosity extremes.
Pack support
Control flexible bottles, pouches and wide-mouth pots during filling and closing.
Cleanability
Confirm drainage, strip-down, seals, dead legs and repeatable reassembly.
Closure or seal checks
Measure cap, foil, lid or pouch-seal results using the actual filled product and pack.
Closing, sealing, labelling and coding are part of the same acceptance test
Mayonnaise can be packed with screw or flip-top caps, foil seals, snap lids or pouch seals. Product on the finish or flange can cause leaks and poor presentation, so nozzle cut-off and pack transfer should be assessed together with the closure equipment.
Agree measurable results for dose, presentation, closure or seal, label, code, reject handling and sustained output. A fast isolated filler cycle does not prove an integrated production line.
Scale automation from weekly demand—not headline speed
Convert saleable weekly demand into available production minutes, then allow for warm-up, replenishment, cleaning, changeovers, inspection, rejects and operator tasks. Desktop, compact, two-head and multi-head systems are planning bands rather than guaranteed capacities.
Desktop or semi-automatic
Manual pack presentation with assisted filling, capping or labelling. Prioritise flexibility and manageable cleaning.
Compact or two-head line
Coordinated conveyor stages, repeatable presentation and selected automatic feeding or closing.
Multi-head automatic line
Integrated container, closure, inspection and end-of-line handling with a defined acceptance run.
Representative trial checklist
Use the most difficult normal combinations—not only an ideal batch and pack.
- Lowest and highest normal product temperature.
- Product after actual pumping and holding time.
- Air content, density and visual texture.
- Smallest neck or narrowest sealing margin.
- Dose repeatability and nozzle cut-off.
- Cap, foil, lid or pouch-seal integrity.
- Changeover between pack formats or recipes.
- Cleaning, drainage and allergen-control requirements.
Common questions
Positive-displacement piston or pump-based filling is often considered, but the choice depends on viscosity, shear sensitivity, air, dose, pack and cleaning. Trials with the production feed method are important.
Review mixing, transfer pump, hose routing, hopper refill and filling profile. The line should avoid unnecessary recirculation or high-speed product handling.
Yes, where the pouch can be opened and supported reliably and the nozzle protects the seal area. Seal integrity must be proven with the actual product.
Many mayonnaise applications are cold or ambient fill, but product safety and preservation are recipe-specific responsibilities requiring appropriate validation.