Recognise the symptom before changing settings
Describe what changes, where it first appears and whether it follows a product batch, packaging batch, filling head, lane, speed, temperature or time in the run. Typical observations include:
- some packs contain many pieces and others few
- liquid fill is consistent but solids are not
- distribution changes as the hopper empties
- particles are damaged during filling
Likely causes to separate
A symptom can have several unrelated causes. Treat the following as hypotheses to test rather than a list of settings to change at once.
- insufficient or excessive agitation
- outlet position draws an unrepresentative phase
- particles settle or float faster than the batch is used
- valves or nozzles screen out larger pieces
- recirculation damages or segregates inclusions
Check in this order
Check 1
Sample the vessel at top, middle and outlet over time.
Check 2
Count or weigh inclusions in packs by sequence.
Check 3
Observe particle movement at full and low vessel levels.
Check 4
Check minimum passage and shear through every component.
Check 5
Compare gentle agitation patterns.
Corrective actions to evaluate
After the cause is demonstrated, select the least disruptive correction that returns the process to a safe, repeatable and approved state.
- use controlled sweep or low-shear agitation
- select outlet and vessel geometry for representative draw-off
- increase unrestricted product passages
- reduce damaging recirculation
- meter liquid and solids separately where one-path dosing cannot meet the requirement
Prevent the problem returning
- define particle distribution acceptance criteria
- trial the start and end of batch
- record particle size range and density
- validate agitation speed for each formulation
Record evidence, not only the final setting
Capture the product and packaging batches, machine recipe, head or lane, speed, temperature, vessel level, symptom frequency, intervention and post-correction results. This creates a usable centreline and allows recurring loss to be prioritised through OEE or downtime analysis.
Common questions
What is the first check for uneven particles or inclusions between filled packs?
Sample the vessel at top, middle and outlet over time.
What commonly causes uneven particles or inclusions between filled packs?
Common causes include insufficient or excessive agitation, outlet position draws an unrepresentative phase, particles settle or float faster than the batch is used.
Should the machine be adjusted immediately?
Change one controlled variable at a time after the measurement method, product condition, packaging and safety state are confirmed.
When should production be stopped?
Stop and follow the site safe-isolation and escalation procedure when there is risk of injury, contamination, fire or explosion, uncontrolled product release, damaged guards, unsafe pressure or an unverified quality result.
What information should be recorded?
Record product and pack batch, recipe, machine settings, filling head or lane, time, temperature, speed, symptom, corrective action and the evidence that performance returned to the approved condition.