Checkweigher reject validation and challenge-test guide

Define challenge packs and acceptance

Create controlled packs representing acceptable, low, high and any critical missing-component conditions. Identify and secure them so they cannot enter saleable stock. Verify their reference values before use.

State the required result for each pack and the permitted number of attempts. A challenge test should not become a repeated exercise until the machine happens to pass.

Test tracking at production speed

Introduce challenges before the product sensor with normal pack spacing and line speed. Confirm that the measured pack remains correctly associated with the reject command through acceleration, gaps and accumulation.

Test consecutive rejects and packs near the minimum spacing. These conditions can expose tracking logic that a single isolated pack does not.

Test reject and fail-safe conditions

Verify physical removal, reject confirmation, secure collection and the response to a full bin, open bin, low air, failed actuator, lost confirmation or stopped downstream conveyor.

Where risk requires it, the line should stop or quarantine product when the system cannot prove that a rejected pack was contained.

Record and investigate results

Record date, time, line, product, recipe, challenge identity, reference value, measured value, reject response, operator and outcome. Link failures to affected production and corrective action.

Trend repeated marginal results. A slowly worsening challenge result can identify belt wear, vibration, contamination or drift before an outright failure.

Information to prepare

• Approved low, good, high and defect challenge packs
• Reference values and identification controls
• Normal speed and minimum spacing test
• Consecutive-reject and tracking test
• Reject confirmation and secure-bin check
• Failure-mode and alarm tests
• Signed result and affected-product response