Product and packaging evaluation
Our sample-testing process evaluates how your material feeds, doses and seals with the proposed filling arrangement. We use the product and packaging requirements to define the trial question, the configuration to evaluate and the observations needed for selection. Powder flow, nozzle cutoff, package handling and the seal area are assessed as connected parts of the process.
The trial plan identifies the sample, target fill, package drawing and operating conditions. A sauce project may focus on particles and clean cutoff; a powder project may focus on replenishment and dose consistency. The findings then inform dosing-head selection, product-contact details and the acceptance plan for the built machine.
Failure points a short trial can expose
The most useful sample tests target a known failure mode rather than a general impression of the machine. These are worth seeing on your own product before you commit to a dosing method.
- Powder bridging or rat-holing in the hopper, which starves the auger and shows up as underweight packs after several minutes of running
- Drips and stringing from the nozzle after cutoff on viscous sauces, honey or lotions, which land on the seal area
- Seal contamination from powder dust or product film in the jaws, visible as channels, wrinkles or weak spots across the seal
- Particles in a sauce that lodge in a valve or get trapped in the seal
- Cap-cavity overfill, where powder or honey sits above the rim and stops the foil from lying flat
- Foam or entrained air that changes the fill level from one pack to the next
What to send for a representative test
A result is only as good as the material behind it. Send production material rather than a retail product taken off a shelf, or a lab batch made with different ingredients.
- Production material, or a representative blend labeled with its batch and any differences from production, in enough quantity for a continuous run rather than a handful of doses
- Film, pouches, caps or foil from your intended packaging supplier, since seal behavior depends on the specific laminate or liner
- The target fill with its unit, the filling temperature, and handling notes such as settling, separation or moisture pickup
- A dimensioned pack drawing and a short list of the checks that will decide the project, in order of importance
Trial preparation and handling
Before shipment, we agree the receiving contact, sample quantity, packaging material and handling conditions with you. The trial plan records the material identity, target dose, package revision and measurements to collect. Temperature-sensitive or regulated samples need a suitable shipment and holding arrangement, with freight and customs responsibilities identified.
The planned record includes the sampling method, settings and relevant photographs or video. Defining these items before the run keeps the results connected to the selection question and gives both teams a clear basis for discussing configuration changes.
Measurements worth asking for
Ask for measurements you can later compare with your own acceptance criteria. Net fill weights should come from a stated scale, with the tare method and the number of packs recorded. On multi-lane equipment, keep samples separated by lane so one weak lane doesn't hide inside an average.
Agree the closure-check method with the packaging and quality teams. Record visual seal-area observations and the applicable integrity-test results with the sample count and package specification. Cap-cavity work calls for fill height against the rim and a check of whether the foil lies flat. When the powder is hygroscopic, note the room temperature and humidity alongside the weights.
Use trial findings in the configuration
The trial record connects the material, packaging and setup with the observed dosing and seal behavior. We use it to identify configuration actions, such as a change to feeding, nozzle cutoff, product clearance or seal settings. Where the project uses several products or pack sizes, the record identifies which conditions need separate evaluation.
The next project step connects the selected equipment with its proposed performance conditions and acceptance criteria. Keep the sample identity, measurements and configuration revision together so the FAT plan and subsequent site work use the same reference. Contact our team with your product and package details to arrange the evaluation scope.
Common questions
How much product should I send for a filling machine trial?
Send enough material for a continuous run. A handful of test doses isn't enough, because problems such as powder bridging or nozzle drips often show up only after several minutes. The right amount depends on the dose, the pack size and the dosing method, so put the quantity in writing before shipping. Too little material usually makes the trial inconclusive.
Can a sample test show whether my powder will bridge in the hopper?
It can give an early indication if the test runs long enough with your real blend under realistic room conditions. Ask for fill weights recorded over the run rather than a few spot checks, since bridging usually shows up as a gradual drift toward underweight packs. Humid conditions and fine, cohesive blends deserve particular attention.
What should a filling sample test report include?
The product batch and packaging used, the setup and settings, and the measurements with their method and sample size. Add photos of the finished packs and any unresolved questions, and list weights from multi-lane equipment by lane. Without the method and conditions, the numbers can't be compared with your acceptance criteria later.
Is there a charge for filling machine sample testing?
Trial quantity, handling, schedule and any charges are agreed for the project before material is shipped. Send the product and packaging details so our team can define the evaluation and receiving arrangement.