Direct answer
Set a fill target from the actual process mean and spread, not a guess. Measure tare and product variation separately, confirm density where volume is declared from mass, compare the process with the legal or commercial limits, and improve capability before relying on extra overfill.
Measure the process correctly
Collect consecutive packs across a representative run, including replenishment, speed and temperature changes. Record gross, tare and net values using suitable equipment.
Do not mix different containers or fill heads without identification; otherwise the source of variation is hidden.
Separate centring from variation
A stable narrow distribution with a low mean needs centring. A wide distribution needs root-cause improvement before the target can be reduced safely.
Analyse by nozzle, head, lane, container batch and time to identify repeatable patterns.
Account for tare and density
Container, lid and label weights can vary materially relative to a small fill. Use representative tare values or a process that measures net content appropriately.
Where a volume declaration is inferred from mass, control product density at the relevant temperature and formulation.
Use feedback carefully
Checkweigher feedback can adjust the filler mean, but correction rules should avoid chasing individual noise. Use a filtered trend, cap the adjustment and alarm when spread or drift exceeds a limit.
Retain set-point, adjustment and intervention records with the batch.
Information to prepare
- Consecutive gross and tare sample data
- Results separated by filling head or lane
- Nominal quantity and applicable TNE
- Density and temperature evidence where relevant
- Mean, range and standard deviation trend
- Target and feedback rule
- Corrective action and product-hold procedure
Automatic Filling Machines
Automatic filling routes matched to product behaviour, pack format and required control.
Official references
Check the current source before relying on dates, thresholds or legal duties.