HTPHow to PackageProduction answers by Lancing UK
Pack formats

How do I reduce damaged and rejected sachets?

Practical guidance for sachets: reduce product loss, damaged packs, film waste and avoidable rejects.

Answer format: direct explanation, ordered checks and relevant solution routes. . Application-specific engineering review is still required.

Direct answer

For sachets, measure where material or product is lost and calculate waste per good pack. A pack must remain clean, stable and correctly orientated through every transfer, filling, closing, labelling and inspection stage. Start by separate product, packaging and rework waste and record damage rate, jam rate, position repeatability and finished-pack integrity. Make one controlled change at a time so the original cause is not hidden by several new settings.

Production environment relevant to pack formats
Work safely: Isolate machinery before inspection or clearing. Follow the machine manual, site procedures and competent-person requirements.

What usually causes this?

  • overfilling, over-application or excessive trim used as a safety margin
  • A change in dimensional and material variation or base stability and centre of gravity.
  • start-up and changeover settings not standardised
  • The equipment or handling method not being set for small single-dose flexible packs with demanding dose and seal control.
  • damaged or misfed packaging creating repeated rejects

Checks to make in order

  1. Separate product, packaging and rework waste
  2. Record damage rate, jam rate, position repeatability and finished-pack integrity using a representative sample.
  3. Weigh or count loss during start-up, running and changeover
  4. Check neck, opening or sealing geometry, surface condition and static and guides, transfers and pack support.
  5. Record the reason for every reject in a sample period
  6. Check whether waste changes with speed or pack size
  7. Calculate the financial value of giveaway and damaged packs

How to decide the next step

Sachets involves small single-dose flexible packs with demanding dose and seal control. Prioritise the largest measured loss, then verify that the change does not reduce seal, dose or closure quality.

If adjustment and maintenance cannot hold the required result across the complete product and pack range, compare the machinery route against a written acceptance test. The important comparison is sustained good output—not only maximum cycle speed.

What to include in your production brief

Supplying the information below makes it much easier to distinguish a setup problem from a machinery or packaging limitation:

  • Dimensioned pack drawing
  • Minimum and maximum pack samples
  • Material and supplier specification
  • Closure or seal components
  • Required orientation and label area
  • Target line rate
  • Samples that represent sachets
  • A short video of the current process and fault

Relevant solution websites

These specialist sites match the production process discussed above. Final suitability should be confirmed with samples, output, site and acceptance information.

Sachet Filling MachinesForm Fill and SealCoding Machinery

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Common search questions

Questions customers also ask

Open a question for a concise answer, then use the detailed guide above for the full production checks.

What should I check first for sachets?

Separate product, packaging and rework waste

What commonly causes this problem with sachets?

Common causes include overfilling, over-application or excessive trim used as a safety margin; A change in dimensional and material variation or base stability and centre of gravity.; start-up and changeover settings not standardised.

How can I prove that an adjustment has worked for sachets?

Record a representative baseline, change one variable at a time and repeat the same measurement over enough packs to show that the result is stable rather than a one-off improvement.

When should I consider a different machine or production method for sachets?

Consider a different route when correct setup and maintenance cannot hold the required quality and sustained output across the complete product and pack range.

What information should I send before asking for a solution for sachets?

Include Dimensioned pack drawing; Minimum and maximum pack samples; Material and supplier specification; Closure or seal components.

Which solution website is most relevant to this question?

The clearest starting point on this page is Sachet Filling Machines. Final suitability still needs to be confirmed using the actual product, packaging, output and site information.