Describe inclusions in more than one dimension
Nominal particle size is only a starting point. A long fibre can bridge a valve even when its diameter is small, while a soft cube may deform and pass through a smaller opening.
| Characteristic | Record | Why it matters |
|---|---|---|
| Maximum size | Length, width and thickness of the largest credible piece. | Sets minimum clearances and nozzle margin. |
| Shape | Round, cubed, sliced, stringy, leafy or irregular. | Influences bridging, orientation and valve passage. |
| Firmness | Soft, compressible, brittle, fibrous or hard. | Determines damage risk and whether pieces can deform. |
| Loading | Typical and maximum percentage/number of pieces. | Affects probability of blockage and distribution per pack. |
| Density | Float, suspend or settle relative to the carrier. | Determines mixer and hopper strategy. |
| Variation | Batch, seasonal and supplier extremes. | Defines the true trial window. |
Audit every restriction from vessel to container
Vessel outlet
Check the outlet, screen, elbow and any reducer before the transfer pump.
Transfer pump
Confirm pump type, rotor/stator or chamber clearances and shear effect.
Hoses and fittings
Record internal diameter, bends, couplings and abrupt changes in section.
Filler inlet and manifold
Review check valves, ports, tees and distribution to multiple heads.
Metering chamber or pump
Confirm the dose mechanism passes pieces without trapping or cutting them.
Nozzle and cut-off valve
Check the smallest effective opening under real actuation, not only nominal bore.
Container opening
Leave practical clearance for pack tolerance, nozzle misalignment and piece orientation.
A large hose or nozzle does not solve a restrictive check valve, elbow, manifold or partially open cut-off.
Maintain distribution without turning the product into purée
Agitation should achieve the required suspension or circulation with the least damage to texture. Mixer geometry, speed, vessel shape, batch depth and dwell all matter.
Settling pieces
Use controlled agitation or recirculation to prevent heavy inclusions concentrating at the hopper bottom.
Floating pieces
Draw product from a zone that receives the intended mix and prevent a surface raft.
Fragile inclusions
Use low-shear movement and minimise repeated pump passes or narrow high-speed gaps.
Viscous carrier
Ensure the mixer can move the bulk product at its normal filling temperature, including low batch levels.
Sample fills from the start, middle and end of a batch. Weighing the complete dose alone may hide poor piece distribution.
Use positive transfer and generous passages where the product requires it
Piston, rotor, lobe and other positive-displacement approaches may be considered depending on product, dose, cleaning and output. The useful question is whether the complete selected mechanism handles the product window.
| Design feature | Potential benefit | Must still be verified |
|---|---|---|
| Rotary or large-bore valve | Can provide a more open path for soft pieces than a small conventional check valve. | Actual port geometry, timing, cleaning and product damage. |
| Mixer hopper | Can keep inclusions distributed near the filler. | Mixer speed, low-level performance and texture impact. |
| Large outlet/nozzle | Reduces restriction and can improve cut-off for chunky products. | Container opening, drip control and fill accuracy. |
| Short product path | Reduces retention, heat loss and opportunities for bridging. | Layout, safe access and refill method. |
| Individual head control | Allows tuning or isolation in a multi-head system. | Balanced flow and repeatability across heads. |
Verified reference: low-level rotor-pump depositor
A first-party Lancing quotation for a specific jam/chutney application used the LU-DTGT900U low-level depositor with an 1800-series rotor pump, 100 L mixer hopper and 38 mm anti-drip outlet. The stated application included fills up to 750 ml and pieces around 8–10 mm, with final performance subject to representative trials.
Build a trial that can expose blockage and distribution problems
- Supply the largest, longest and firmest expected inclusions—not a blended sample.
- Test normal and maximum inclusion loading at normal fill temperature.
- Run long enough to expose settling, floating or hopper-level effects.
- Inspect pieces after transfer and filling for unacceptable cutting or crushing.
- Measure piece distribution across consecutive containers and across the batch.
- Include stop/restart, low hopper level, refill and clean-down conditions.
- Record the exact restriction or event behind every blockage or misfill.