1. Define the product and operating window
Begin with measurable limits rather than a generic description such as “thick sauce”. The machine must handle the product at the temperature, consistency and inclusion level encountered during real production.
Flow behaviour
Record whether the product pours, strings, traps air, separates, foams or changes rapidly as it cools.
Inclusions
Measure the largest and firmest pieces, fibre length, seed load and the tendency to bridge or settle.
Batch consistency
Compare early, middle and late batch behaviour; check whether agitation changes texture or piece integrity.
Cleaning boundary
Define strip-down, flush, allergen changeover, wash temperature and acceptable retained product.
A successful trial should cover representative low- and high-viscosity batches, the largest expected pieces and the normal production temperature window.
2. Confirm the primary pack and presentation method
Container geometry determines how packs are accumulated, spaced, located, filled and closed. Supply production-quality samples, not only drawings.
| Pack input | Why it matters | What to record |
|---|---|---|
| Opening | Sets nozzle clearance and piece passage margin. | Internal diameter, neck finish, lip condition. |
| Body geometry | Affects guiding, label presentation and stability. | Diameter/width, height, taper, panels and seams. |
| Material | Determines heat response and handling limits. | Glass, PET, PP, laminate or other construction. |
| Closure or seal | Controls cap handling, torque, seal pressure and timing. | Type, size, liner, application method and supplier. |
| Decoration | Can impose orientation or dry-surface requirements. | Label size, panel, sleeve, code location and datum. |
Confirm whether the operator manually places packs, a turntable or conveyor feeds them, or a full automatic infeed is required. Unstable, lightweight or irregular packs may need side guides, pucks or bespoke change parts.
3. Prepare the product and empty pack
Product transfer
Move product from the process vessel to a controlled buffer or filler hopper without excessive shear, aeration or heat loss.
Hold and condition
Use an appropriate vessel, mixer, agitator or temperature-control method to keep the product inside its operating window.
Inspect empty packs
Control chips, cracks, deformation, dust, foreign matter and presentation before filling.
Rinse or treat where required
Select inversion, air, water or another validated method only where the process requires it; manage drainage and carry-over.
Synchronise release
Present one pack at the correct position and spacing so the filler can dose without collision or contamination.
Preparation equipment must not create a new bottleneck. Include vessel replenishment, empty-pack loading, drain time and rejected-pack removal in the line balance.
4. Fill, control cut-off and apply the closure
The filler, nozzle and container-location system should be treated as one functional unit. The selected method must deliver the intended dose while protecting the pack lip and closure area.
Dose control
Set the repeatable fill method and define how accuracy is checked under stable production conditions.
Nozzle behaviour
Control drips, tails, stringing, splashing, diving motion and contact with the product or pack.
Headspace
Maintain the headspace needed by the product, closure, thermal route and commercial presentation.
Closure application
Feed, place and tighten or seal without cross-threading, skew, contamination or pack damage.
Product on the jar finish, foil land, pouch seal zone or cap thread can cause leaks and false rejects. Clean cut-off and controlled pack movement are therefore line-critical.
5. Stabilise the pack before labelling and coding
Immediately after filling and closing, the pack may still be hot, flexible, wet, pressurised or covered in product residue. Define the required condition at the labeller.
Closure dwell or verification
Allow the closure or seal to settle, then verify relevant presence, position, torque, vacuum or seal criteria.
Cooling or equilibration
Control cooling time, pack spacing and thermal shock where a hot-filled product must reach a stable downstream condition.
Drying and cleaning
Remove external moisture or product where labels, sleeves, ink or cases require a clean, dry surface.
Labelling and coding
Apply the consumer label, tamper evidence and readable batch/date information in the agreed position.
Inspection
Check selected critical features and route non-conforming packs into a controlled reject process.
6. Accumulate, collate and protect packs for distribution
End-of-line equipment should accept the real output pattern, including short stops and bursts. A small accumulation allowance can prevent a labeller or case-packing task from stopping the filler immediately.
Accumulation
Define buffer duration, pack pressure, heat retention and first-in/first-out needs.
Collation
Set the count and pattern for trays, sleeves, shrink bundles or cases.
Secondary identification
Apply case labels, batch information or barcodes where required by the distribution route.
Pallet and dispatch
Confirm case weight, orientation, stacking, pallet pattern and handling constraints.
Do not accept a filler solely on isolated cycles when the project is an integrated line. Agree a representative sustained run, pack-quality checks, reject method, changeover and clean-down review.
7. Build an application trial and acceptance plan
Define pass/fail evidence before the trial. This separates machine capability from assumptions and makes quotation scope clearer.
| Evidence | Suggested check | Project decision |
|---|---|---|
| Representative materials | Normal and worst-case product; production packs, closures and labels. | Samples approved for testing. |
| Output basis | Sustained packs/minute including normal operator tasks. | Required and stretch rates recorded. |
| Pack quality | Dose, cut-off, headspace, closure/seal and presentation. | Measurable acceptance window agreed. |
| Changeover | Largest/smallest pack and product variants. | Tools, parts and target method defined. |
| Cleaning | Drain, recovery, strip-down and reassembly. | Responsibility and expected procedure agreed. |
| Interfaces | Upstream/downstream speed, height, direction and controls. | Interface schedule issued. |