Why do uneven fill levels occur?
Typical causes
Uneven fill levels are usually not caused by the dosing machine itself, but by the interplay of product, feed, dosing technology, and line design. Only when all components are optimally coordinated will each glass receive the same fill level.
What are the effects of uneven fill levels?
Even small differences in fill quantity can lead to complaints, increased raw material consumption, or problems in complying with legal requirements.
This is particularly critical for high-quality foods such as soups, sauces, delicatessen items or products with solid ingredients.
The most common causes
1.
Fluctuating product pressure
2.
Air inclusions in the product
3.
Inappropriate dosing technology
4.
Incorrect product feed
5.
Different product viscosities
How can uneven fill levels be avoided?
The most important requirement is not just a precise dosing system.
Equally important are:
✔ constant product feed
✔ Uniform product printing
✔ suitable pump technology
✔ Optimally adjusted line speed
✔ regular calibration
💡 Expert tip from Machines4FoodIndustry
"Many manufacturers initially suspect a problem with the dosing machine."
In practice, however, it turns out that uneven fill quantities often result from the interaction of several process steps.
That's why we always analyze the entire production line – not just a single machine."
- Paweł Grabiec
Managing Director Marba Sp. z o.o.
Engineering partner of Machines4FoodIndustry
Suitable solutions
Filling machines for chunky foods
Piston fillers and dosing systems for liquid and viscous products
Lid feeding systems
Conveyor technology for production lines
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FAQs
How exactly can the fill quantity deviate?
The permissible deviations in fill quantity depend on the specific product, the packaging, and legal requirements. Crucially, however, the dosing process must be reproducible and reliable. An optimally calibrated dosing system helps ensure consistent fill quantities and avoid complaints and product losses.
Which products are particularly critical?
Products with solid components or varying viscosity are particularly challenging, for example:
- Soups with meat, vegetables or mushrooms
- Ready meals
- goulash
- Jams with pieces of fruit
- Chutneys
- Sauces with garnishes
- deli salads
- Pesto, etc.
For these products, the dosing technology, mixing system and product feed must be perfectly coordinated so that each glass has the same composition.
Can every dosing system be calibrated?
In principle, dosing systems can be calibrated and adapted to different products. However, it is crucial that the entire production line is taken into account. Fluctuating fill levels often do not originate from the dosing machine itself, but from factors such as product feed, viscosity, air in the product, or line speed. Therefore, at Machines4FoodIndustry, we always analyze the entire process to ensure consistently precise dosing.
Why is a high-quality dosing machine often not enough on its own?
Even the best dosing machine can only operate precisely if product feeding, mixing technology, conveying technology, and line speed are optimally coordinated. In practice, therefore, dosing accuracy is not determined by a single machine, but by the interaction of the entire production line.
👉 That is precisely why we do not develop standard solutions, but rather individually tailored production lines for the food industry.
Problems with uneven fill levels?
Our experts analyze your production line and develop a customized solution for consistent and reproducible dosing.