Start with the exact pot, rim and closure combination
A pot is not simply a short jar. Lightweight walls, nested supply, broad openings and heat-seal lands create different handling and sealing requirements.
Pre-denested pots
Simpler for lower output but requires an operator to present each pack consistently.
Automatic denesting
Supports higher output when nested pots separate reliably without static, deformation or double feeds.
Snap-on lids
Require controlled lid presentation and force without crushing or distorting the filled pot.
Foil or film seals
Need a clean, supported land plus compatible material, temperature, pressure and dwell.
Control denesting, location and base support
Pots can ovalise, bounce or climb over guides. Test the full dimensional tolerance and any printing, flange variation or static behaviour.
Separate one pot
Prevent doubles and confirm that the bottom pot releases from the stack.
Transfer without deformation
Support the body and flange so the pot reaches the filling station square.
Locate the opening
Centre the mouth below the nozzle and hold the pot against filling reaction forces.
Support the sealing land
Provide a flat, repeatable support under the rim during foil sealing or lidding.
Discharge gently
Avoid squeeze pressure or transfer gaps that disturb a warm, recently sealed pack.
Fill quickly while protecting the sealing land
Wide openings make filling access easier, but product can splash onto the rim when the dose starts, stops or the pot moves too early.
- Set nozzle height, diameter and cut-off around the pot opening and fill profile.
- Use a product path that suits viscosity, temperature and inclusions.
- Review rising fill or multi-stage speed where splash or air entrapment is a concern.
- Allow the product to settle before a foil or lid is applied.
- Inspect the sealing land and define how contaminated pots are rejected or cleaned.
Agree the acceptable condition of the rim after filling and include it in the trial—not just the delivered dose.
Match the sealing method to the pot material and distribution route
| Method | Control points | Typical verification |
|---|---|---|
| Snap-on lid | Lid orientation, placement, application force and pot support. | Presence, height, full engagement and visual condition. |
| Heat-sealed foil | Material compatibility, rim support, time, temperature and pressure. | Peel, leak and visual seal checks to an agreed method. |
| Pre-cut membrane | Pick/place reliability, static, orientation and seal land. | Position and complete bond around the circumference. |
| Overcap plus membrane | Sequence, headspace and protection of the primary seal. | Primary seal result plus overcap engagement. |
Seal parameters must be established with the actual pot and lidding material supplier information and confirmed through representative trials.
Code and label a shape that may not be cylindrical
Decoration options include side labels, wrap labels, top labels, base codes, sleeves and pre-printed pots. Taper and flange overhang can limit label size or create wrinkles.
Top label
High visibility and potential tamper-evident bridge, but lid flatness and condensation matter.
Side label
Works on suitable straight panels; taper, ribs and moulding marks need evaluation.
Sleeve
Can cover complex geometry but requires material and shrink-process development.
Direct code
Batch and date code location must stay readable through chilling, handling and secondary packing.
Trial the pack under realistic filling, sealing and cooling conditions
| Check | Questions to answer |
|---|---|
| Denesting | Do all pots separate one at a time across supplier tolerances? |
| Support | Is the body/rim held without deformation at fill and seal stations? |
| Rim cleanliness | Does the product or nozzle contaminate the sealing land? |
| Seal | Does the agreed material produce an acceptable seal through the operating window? |
| Handling | Can the sealed pot transfer, accumulate and collate without lid lift or distortion? |
| Changeover | Which guides, nests, seal heads or recipes change between sizes? |