Plan Automation Technology Blog

Avoid Over & Underfilling with a Product Inspection System

Posted by Mat Bedard on Tue, Sep 26, 2017 @ 07:09 AM

These 3D images can show how full a tray of frozen food is based on the mass of the package--not just a visual inspection.There are billions of different packages that are filled every day around the world. A package can mean a jar, bottle, box, tube, a can or any other container filled with a product. According to the law, all prepackaged goods should display the volume or net weight and the number of pieces. In the modern world, the value of a product is much more than just its functions and sealable elements including image and safety.

Some simple products incorporate these elements because they can influence their compliance with the regulatory requirements. You should conduct product inspection checks thoroughly, including checking whether packages contain what they are labeled in legal quantities.

Minimal Overfill to Cut Costs

The process of filling is subjected to some factors that can cause fluctuations in the weight of packaged goods. However, the fluctuation of weight shouldn’t cause the net weight of any package to fall below the indicated net weight. There are regulations that specify the underfill quantities. To eliminate the risk of consumer complaints, some manufacturers make overfills. Although overfilling will eliminate customer complaints, it can eventually lower revenue. Therefore, you need to accurately monitor and manage data through a product inspection system. This will keep the process controlled and avoid expensive overfill costs.

Incorrect filling will cost your business a lot of money. Overfilling will lead to expensive product giveaway, while underfilling will lead you into problems with weights and measurement regulators. Incorrect filling levels and unplanned downtime is an expensive combination, but it can be avoided. In most cases, when overfill or underfill is identified, the solution is to stop production and having the fillers recalibrated. This will not only affect your uptime but also lead to waste if the problem isn’t detected early.

Available Solutions: Random Sampling and 100% Inspection

Static scales should be used to authenticate compliance with the net content produce and legislation package weight verification reports. A product’s specific processes and parameters, economic and financial factors are the main determinants on a product line. You need to have a deep understanding of the filling machine package and scatter limits for you to select the right and best sampling method, statistic scales and 100% product inspection system to check all packages.

5 Reasons Why You Should Perform a Fill Level Inspection

  1. Minimum contents legislation: This can dictate that the contents labeled on a container are the minimum required weight to be in the container. An underfill product inspection system can be used to control this.
  2. Customs & exercise: If you are packing high duty products, customs and excise will take charge of overfilling because duty is calculated depending on the contents that are labeled on a container. An overfill product inspection system will help you to avoid customs and excise penalties.
  3. Average contents legislation: Many countries have adopted the use of an averaging system that is derived from the contents labeled on the container. Inspection of both under and overfill can help you take control of the average.
  4. Yield: Overfilling content is a waste of your product, and this can minimize revenue. Most manufacturing companies judge their performance depending on their yield. An overfill product inspection system will help you to manage your yield.
  5. Aesthetics: Most products have a certain level of brand identity, and their appearance is important when making a sale. However, even after all packages have been approved to fall within the legal guidelines, their fill levels will give them different looks. Many brand owners choose to use under and overfill product inspection systems to control how their products are presented to the end consumer.

Overfills are almost always very expensive, even when using a modest output rate. Therefore, minimizing overfills by using a product inspection system will effectively control giveaways and expenses without having to increase personnel costs.

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Topics: Product Quality, X Ray Inspection for Food, Food Product Inspection