A practical production route
Use the eight stages below to compare the complete route for your product, from preparation and pack handling through to dispatch. For concealer, the critical issues are product tails, air pockets, inconsistent dose weight and smearing around the neck.
Define the product window
Measure the production range for concealer: fill volume or weight, density, viscosity or flowability, temperature, largest inclusion, foam, chemistry and shelf-life process. Select equipment against the worst case, not the easiest sample.
Prepare and feed consistently
Prepare concealer to a repeatable specification and supply the filler through a hopper or short, large-bore transfer route that avoids excessive restriction. Control batch-to-batch variation and avoid long, restrictive or difficult-to-clean pipework.
Apply the required treatment
Mix concealer without entraining excess air. Define a stable temperature and resting time before filling so viscosity and dose behaviour remain repeatable.
Prepare the empty pack
Protect empty single-serve sachets from dust and distortion, verify seal-layer compatibility and control presentation into the filling station. Keep the seal area free from product.
Fill accurately and cleanly
Use a piston, servo-piston, progressive-cavity or positive-displacement filler. Manage stringing with shut-off nozzles and match acceleration to viscosity. Set the nozzle and container handling so the outside of the single-serve sachets remains clean for closing and labelling.
Close or seal the pack
Keep the seal area clean and apply formed heat seals at controlled time, temperature and pressure. Validate seal strength, peel behaviour and leak resistance on production material.
Label, code and verify
Use pre-printed film or apply pressure-sensitive labels to a flat, clean area of the single-serve sachets. Print and verify batch, date and traceability data without weakening the seal.
Inspect and pack for distribution
Check fill quantity, pack integrity, code and presentation before accumulating or case packing. Confirm the finished single-serve sachets survives handling, sleeve wrapping, case packing, palletisation and transport.
Equipment options for concealer
These machine types provide an initial route. Dose range, contact materials, output, utilities, change parts and controls should be agreed after a representative product and pack trial.
Recommended filling routeAutomatic servo piston filling machine
A practical starting point for concealer: piston, servo-piston, progressive-cavity or positive-displacement filler with product-specific contact parts and controls.
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Closing and sealingPouch and flexible-pack sealing
Seal preformed packs or form film around the measured dose, with coding and seal-area control.
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Labelling and codingAutomatic labelling system
Apply labels and traceability data to single-serve sachets, with inspection where mix-up risk justifies it.
View Lancing solutionsEngineering, safety and quality controls
Product behaviour
Test viscosity, density, foaming, particle size or flowability using production-representative concealer. Manage stringing with shut-off nozzles and match acceleration to viscosity.
Operator protection
Guard access to moving tooling and control exposure to concealer. Address product tails, air pockets, inconsistent dose weight and smearing around the neck in the machinery and process risk assessment.
Cleaning and changeover
Plan for quick-release product-contact parts or a validated clean-in-place arrangement. Confirm recovery, flushing, allergen or chemical segregation and safe disposal before purchase.
Pack validation
Run the actual single-serve sachets and formed heat seals through filling, closing, labelling and transit tests. Supplier drawings alone do not show real production variation.
Selecting equipment by weekly throughput
| Weekly volume | Typical equipment level | Planning approach |
|---|---|---|
| Under 500 | Desktop or manual-assist | Prioritise low changeover time, flexible tooling and safe repeatability. |
| 500–2,000 | Compact semi-automatic | Separate filler, closer and labeller can provide a practical step up without a full conveyor line. |
| 2,000–10,000 | Two-head or compact inline | Use controlled product feed, powered conveyors and automatic closing or labelling where labour is the constraint. |
| 10,000+ | Multi-head automatic line | Balance every station, include accumulation and specify inspection, rejection and end-of-line handling. |
Prove the line with your product and packaging
The most useful test uses the final concealer, single-serve sachets, formed heat seals, label and code. Include the most difficult size or formulation, not only the easiest product.
Discuss this applicationCommon questions about filling concealer
What filling machine is best for concealer?
A piston, servo-piston, progressive-cavity or positive-displacement filler is the usual starting point because concealer behaves as a smooth viscous product normally handled by piston, servo-piston, progressive-cavity or lobe-pump filling. The actual choice depends on dose, temperature, inclusions, required accuracy, cleaning regime and output.
Can concealer be filled into single-serve sachets?
Yes, provided the single-serve sachets, formed heat seals and product are compatible. Test dimensional variation, fill temperature, headspace, leakage, closure performance, label adhesion and distribution before specifying the line.
Should concealer be filled hot or cold?
Concealer is commonly handled with held within a defined range because viscosity changes with temperature. The final temperature must come from the validated formulation, preservation method, pack material and closure process.
How do you achieve a clean fill with concealer?
Use a positive shut-off nozzle, tune fill acceleration and position, and keep the single-serve sachets stable. Product trials determine whether a piston, pump or gravity method gives the cleanest result.
How should single-serve sachets be closed after filling concealer?
Keep the seal area clean and apply formed heat seals at controlled time, temperature and pressure. Validate seal strength, peel behaviour and leak resistance on production material.
What output can a concealer filling line achieve?
Output depends on dose size, pack handling, fill time, closure method, cleaning and operator loading. As a planning guide: desktop equipment suits under 500 packs/week, compact systems 500–2,000, two-head lines 2,000–10,000 and multi-head systems 10,000+.
What samples are needed to test concealer?
Supply representative concealer, the complete single-serve sachets, formed heat seals, labels and any coding specification. Include the full product range, especially the highest viscosity, largest inclusion or most difficult pack size.