Find the visible problem
Waste and giveaway in packaging production
Reduce product loss, damaged packs, film waste and avoidable rejects. Start with measured evidence, identify the first loss of control and then use the relevant answer for your product, pack or process.
197specific questions
10production areas
5core diagnostic checks
1measurable result: waste per good pack
Start with these checks
Measure where material or product is lost and calculate waste per good pack.
- Separate product, packaging and rework waste
- Weigh or count loss during start-up, running and changeover
- Record the reason for every reject in a sample period
- Check whether waste changes with speed or pack size
- Calculate the financial value of giveaway and damaged packs
Common underlying causes
- Overfilling, over-application or excessive trim used as a safety margin
- Start-up and changeover settings not standardised
- Damaged or misfed packaging creating repeated rejects
- Drips, spills, dust or product left in the machine at the end of a batch
How to use this section
Open the production area below, then choose the question that matches the product, pack or operation. Record the result of each check before changing another setting.
Choose the closest production area
Search these answers →197 answers about waste and giveaway
Liquid filling 15 answers
Troubleshoot thin, foamy, viscous, carbonated, corrosive and flammable product filling.
How do I reduce drips, giveaway and waste when filling thin free-flowing liquids?How do I reduce drips, giveaway and waste when filling foamy liquids?How do I reduce drips, giveaway and waste when filling viscous liquids?How do I reduce drips, giveaway and waste when filling carbonated drinks?How do I reduce drips, giveaway and waste when filling hot-fill liquids?How do I reduce drips, giveaway and waste when filling chilled liquids?How do I reduce drips, giveaway and waste when filling edible oils?How do I reduce drips, giveaway and waste when filling syrups?How do I reduce drips, giveaway and waste when filling sauces and dressings?How do I reduce drips, giveaway and waste when filling creams and lotions?How do I reduce drips, giveaway and waste when filling gels?How do I reduce drips, giveaway and waste when filling liquid suspensions?How do I reduce drips, giveaway and waste when filling corrosive chemicals?How do I reduce drips, giveaway and waste when filling flammable liquids?How do I reduce drips, giveaway and waste when filling solvent-based products?
Powder and piece filling 18 answers
Solve variable weights, dust, bridging, segregation, breakage and hopper-feeding problems.
How do I reduce dust, giveaway and spillage when packing fine powders?How do I reduce dust, giveaway and spillage when packing dusty powders?How do I reduce dust, giveaway and spillage when packing cohesive powders?How do I reduce dust, giveaway and spillage when packing free-flowing powders?How do I reduce dust, giveaway and spillage when packing flour?How do I reduce dust, giveaway and spillage when packing spices and seasonings?How do I reduce dust, giveaway and spillage when packing protein powder?How do I reduce dust, giveaway and spillage when packing milk powder?How do I reduce dust, giveaway and spillage when packing sugar?How do I reduce dust, giveaway and spillage when packing salt?How do I reduce dust, giveaway and spillage when packing ground coffee?How do I reduce dust, giveaway and spillage when packing seeds and grains?How do I reduce dust, giveaway and spillage when packing pet food pieces?How do I reduce dust, giveaway and spillage when packing granules?How do I reduce dust, giveaway and spillage when packing tablets and capsules?How do I reduce dust, giveaway and spillage when packing snack pieces?How do I reduce dust, giveaway and spillage when packing fragile food pieces?How do I reduce dust, giveaway and spillage when packing mixed-size pieces?
Pack formats 22 answers
Find answers for bottles, jars, tubs, cans, pouches, bags, cartons, cases, trays and tubes.
How do I reduce damaged and rejected round bottles?How do I reduce damaged and rejected square bottles?How do I reduce damaged and rejected oval bottles?How do I reduce damaged and rejected glass bottles?How do I reduce damaged and rejected PET bottles?How do I reduce damaged and rejected HDPE bottles?How do I reduce damaged and rejected jars?How do I reduce damaged and rejected tubs?How do I reduce damaged and rejected jerrycans?How do I reduce damaged and rejected metal cans?How do I reduce damaged and rejected vials?How do I reduce damaged and rejected premade pouches?How do I reduce damaged and rejected sachets?How do I reduce damaged and rejected doypacks?How do I reduce damaged and rejected spouted pouches?How do I reduce damaged and rejected open-mouth bags?How do I reduce damaged and rejected folding cartons?How do I reduce damaged and rejected corrugated cases?How do I reduce damaged and rejected trays?How do I reduce damaged and rejected tubes?How do I reduce damaged and rejected bottle rinsing before filling?How do I reduce damaged and rejected returnable bottle washing?
Capping and closures 18 answers
Diagnose leakage, cross-threading, variable torque, cap damage and closure-feeding faults.
How do I reduce damaged, missing or rejected screw caps?How do I reduce damaged, missing or rejected pump caps?How do I reduce damaged, missing or rejected trigger sprays?How do I reduce damaged, missing or rejected flip-top caps?How do I reduce damaged, missing or rejected disc-top caps?How do I reduce damaged, missing or rejected twist-off jar lids?How do I reduce damaged, missing or rejected vacuum jar lids?How do I reduce damaged, missing or rejected ROPP caps?How do I reduce damaged, missing or rejected T-corks?How do I reduce damaged, missing or rejected press-on caps?How do I reduce damaged, missing or rejected snap caps?How do I reduce damaged, missing or rejected child-resistant caps?How do I reduce damaged, missing or rejected tamper-evident caps?How do I reduce damaged, missing or rejected aluminium screw caps?How do I reduce damaged, missing or rejected sports caps?How do I reduce damaged, missing or rejected dropper caps?How do I reduce damaged, missing or rejected stoppers?How do I reduce damaged, missing or rejected bungs?
Labels and coding 18 answers
Resolve skew, wrinkles, bubbles, poor adhesion, unreadable codes and variable-data errors.
How do I reduce wasted round-bottle labels and rejected packs?How do I reduce wasted front and back labels and rejected packs?How do I reduce wasted full wrap labels and rejected packs?How do I reduce wasted tapered-container labels and rejected packs?How do I reduce wasted clear labels and rejected packs?How do I reduce wasted small labels and rejected packs?How do I reduce wasted large labels and rejected packs?How do I reduce wasted top labels and rejected packs?How do I reduce wasted base labels and rejected packs?How do I reduce wasted pouch labels and rejected packs?How do I reduce wasted carton labels and rejected packs?How do I reduce wasted shrink sleeves and rejected packs?How do I reduce wasted tamper-evident neck bands and rejected packs?How do I reduce wasted batch codes and rejected packs?How do I reduce wasted date codes and rejected packs?How do I reduce wasted barcodes and rejected packs?How do I reduce wasted QR codes and rejected packs?How do I reduce wasted shipping labels and rejected packs?
Flexible packaging 14 answers
Solve pouch opening, dosing, film tracking, contamination and seal-quality problems.
How do I reduce film, pouch and product waste during premade pouch filling?How do I reduce film, pouch and product waste during sachet filling?How do I reduce film, pouch and product waste during vertical form-fill-seal bags?How do I reduce film, pouch and product waste during flow-wrapped packs?How do I reduce film, pouch and product waste during pillow bags?How do I reduce film, pouch and product waste during quad-seal bags?How do I reduce film, pouch and product waste during stick packs?How do I reduce film, pouch and product waste during stand-up pouches?How do I reduce film, pouch and product waste during spouted pouch filling?How do I reduce film, pouch and product waste during vacuum pouches?How do I reduce film, pouch and product waste during zipper pouches?How do I reduce film, pouch and product waste during gusseted bags?How do I reduce film, pouch and product waste during shrink film?How do I reduce film, pouch and product waste during sleeve film?
End of line 13 answers
Improve cartoning, case sealing, shrink wrapping, case packing and dispatch inspection.
How do I reduce material waste and rejects during case taping?How do I reduce material waste and rejects during cartoning?How do I reduce material waste and rejects during shrink wrapping?How do I reduce material waste and rejects during sleeve wrapping?How do I reduce material waste and rejects during L-sealing?How do I reduce material waste and rejects during case packing?How do I reduce material waste and rejects during tray packing?How do I reduce material waste and rejects during pallet wrapping?How do I reduce material waste and rejects during print-and-apply labelling?How do I reduce material waste and rejects during checkweighing?How do I reduce material waste and rejects during metal detection?How do I reduce material waste and rejects during dispatch packing?How do I reduce material waste and rejects during induction foil sealing?
Automation and conveyors 19 answers
Solve tipping, back-pressure, transfer, feeding, accumulation and line-integration problems.
How do I reduce damage and rejects with lightweight bottles?How do I reduce damage and rejects with tall unstable bottles?How do I reduce damage and rejects with glass containers?How do I reduce damage and rejects with flexible pouches on conveyors?How do I reduce damage and rejects with cartons and cases on conveyors?How do I reduce damage and rejects with small components?How do I reduce damage and rejects with caps and closures?How do I reduce damage and rejects with pumps and trigger closures?How do I reduce damage and rejects with mixed products on one line?How do I reduce damage and rejects with fragile products on conveyors?How do I reduce damage and rejects with wet containers?How do I reduce damage and rejects with sticky products and packs?How do I reduce damage and rejects with high-speed packaging lines?How do I reduce damage and rejects with multi-format packaging lines?How do I reduce damage and rejects with manual-to-automatic production?How do I reduce damage and rejects with complete filling and packing lines?How do I reduce damage and rejects with component bowl feeding?How do I reduce damage and rejects with production line accumulation?How do I reduce damage and rejects with automatic bottle unscrambling?
Industries 40 answers
Customer-focused answers for food, drink, health, chemical, industrial, packing and logistics operations.
How do I reduce product and packaging waste in bottled water production?How do I reduce product and packaging waste in soft drink production?How do I reduce product and packaging waste in brewery packaging?How do I reduce product and packaging waste in cider production?How do I reduce product and packaging waste in wine bottling?How do I reduce product and packaging waste in spirits and distillery packaging?How do I reduce product and packaging waste in dairy production?How do I reduce product and packaging waste in plant-based drink production?How do I reduce product and packaging waste in sauce and condiment production?How do I reduce product and packaging waste in honey and preserve production?How do I reduce product and packaging waste in edible oil production?How do I reduce product and packaging waste in bakery ingredient production?How do I reduce product and packaging waste in snack and confectionery production?How do I reduce product and packaging waste in coffee and tea packaging?How do I reduce product and packaging waste in spice and seasoning production?How do I reduce product and packaging waste in pet food production?How do I reduce product and packaging waste in seed and grain packing?How do I reduce product and packaging waste in cosmetics manufacturing?How do I reduce product and packaging waste in skincare production?How do I reduce product and packaging waste in personal care production?How do I reduce product and packaging waste in pharmaceutical packaging?How do I reduce product and packaging waste in medical device packing?How do I reduce product and packaging waste in nutraceutical production?How do I reduce product and packaging waste in fragrance production?How do I reduce product and packaging waste in household cleaning production?How do I reduce product and packaging waste in industrial chemical packing?How do I reduce product and packaging waste in agrochemical production?How do I reduce product and packaging waste in paint and coating production?How do I reduce product and packaging waste in adhesive and sealant production?How do I reduce product and packaging waste in lubricant and automotive fluid production?How do I reduce product and packaging waste in construction powder packing?How do I reduce product and packaging waste in laboratory and technical liquid packing?How do I reduce product and packaging waste in contract packing?How do I reduce product and packaging waste in e-commerce fulfilment?How do I reduce product and packaging waste in warehouse dispatch?How do I reduce product and packaging waste in general component assembly?How do I reduce product and packaging waste in hardware and fixings packing?How do I reduce product and packaging waste in wet wipe and hygiene product packing?How do I reduce product and packaging waste in returnable bottle operations?How do I reduce product and packaging waste in recyclable packaging conversion?
Planning and improvement 20 answers
Measure and improve production performance, safety, validation, maintenance, sustainability and investment decisions.
How do I improve line speed?How do I improve format changeovers?How do I improve planned maintenance?How do I improve production downtime?How do I improve product giveaway?How do I improve packaging waste?How do I improve operator workload?How do I improve overall equipment effectiveness?How do I improve machine safety?How do I improve hygienic design?How do I improve production traceability?How do I improve process validation?How do I improve ATEX and hazardous areas?How do I improve sustainable packaging changes?How do I improve second-hand machinery?How do I improve critical spare parts?How do I improve utility planning?How do I improve factory acceptance testing?How do I improve site acceptance testing?How do I improve return on automation investment?
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.
How should I use the Waste and giveaway in packaging production page?
Reduce product loss, damaged packs, film waste and avoidable rejects.
What information should I collect before comparing equipment for Waste and giveaway in packaging production?
Collect representative product and packaging samples, dimensions, format range, current and required good output, measurable tolerances, utilities, site layout and cleaning requirements.
Why should I test the hardest product or pack first for Waste and giveaway in packaging production?
The most difficult product, smallest dose, largest pack or least stable container normally exposes limitations that an easy sample can hide.
How should I compare two machinery routes for Waste and giveaway in packaging production?
Compare sustained good output, quality, changeover, cleaning, operator work, utilities, maintenance and the acceptance test—not only catalogue speed and purchase price.
When should I ask for a sample trial for Waste and giveaway in packaging production?
Ask for a representative trial before committing when product flow, foam, dust, particles, seals, labels, closures or pack stability could materially affect the result.