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During production, overfilling or underfilling errors can occur for various reasons: operator mistakes, incorrect system settings, filling system blockages, or equipment maintenance requirements. Implementing underfill detection alongside overfill checks helps identify and address these issues promptly, avoiding product waste, rework, and rejected or returned products.
Manufacturers can reduce product giveaway from overfilled packages and prevent the sale of underfilled products by conducting a simple underfill detection check to inspect packaged products for correct fill levels. This control measure can help avoid customer dissatisfaction and costly fines associated with non-compliance with consumer regulations.
By installing an inline fill level inspection system with real-time overfill and underfill detection on the production line, manufacturers can perform inline fill level control checks without slowing down production speeds. METTLER TOLEDO Product Inspection systems quickly identify and remove under- or overfilled products and provide immediate feedback to filling equipment.
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Methods for Fill Level Inspection
Fill level inspection equipment can refer to any number of technologies. The type of inspection equipment depends on the product packaging and characteristics.
Checkweighing for Fill Level Control
Inline checkweighing is the simplest and most common method used by manufacturers for fill level control. Dynamic checkweighers weigh items as they move along the production line. A load cell verifies the measured weight against the expected weight. Products that are lighter or heavier than expected—detected via underfill detection and overfill detection—are removed from the production line using an automatic reject device. The type of reject mechanism will vary depending on the product being inspected.
X-ray inspection systems are commonly used to detect physical contamination, but they can also be used to determine the fill level of a product. The system generates an x-ray image of the contents within a container to measure the amount of product present. If the product appears overfilled or underfilled, it can be removed from the production line using a reject device.
It should be noted that x-ray fill level inspection may not be the best method to use for product contents that can settle or shift significantly while traveling on the production line.
Vision inspection uses a smart camera capture an image of the container to visually verify the fill level. Vision systems can also be used to inspect the outside of the package for label verification and print inspection. This method of fill level inspection is only possible when the packaging is not completely opaque.
As with x-ray inspection, vision-based underfill detection may be less accurate when contents shift or settle.
All dynamic checkweighing systems from METTLER TOLEDO are able to send digital feedback to filling equipment. This enables real-time adjustments to filling machine settings, minimizing the need for product rework. If a more serious problem arises with the filling equipment, the systems can report the issue and stop production automatically, further reducing product waste.
More information about our fill level inspection system capabilities can be found on our Optimizing Filling Processes know-how page.
Choosing the most appropriate solution to meet your fill level inspection equipment requirements is easier when you partner with a product inspection equipment provider who can provide options such as:
Local service support to achieve optimal equipment performance
Customized and combination solutions to handle a variety of quality inspection needs
METTLER TOLEDO has decades of experience in designing and manufacturing a range of standard and customized in-line quality inspection solutions. Our overfill and underfill detection solutions are designed to make it easier to control accurate fill levels of your products, resulting in less product waste and protecting against fines and unhappy consumers.
We provide inspection solutions for a range of industries and product types, such as:
This brochure provides an overview of the capabilities and advantages of our combination inspection...
FAQs
How can I control fill levels in manufacturing?
Fill level control is accomplished by adding fill level inspection equipment to the production line. Ideally, it should be placed after or integrated into the filler itself.
There are several types of equipment available for fill level inspection, including checkweighers, x-ray inspection systems, and vision inspection systems.
With the help of fill level inspection equipment, each product can be verified for correct fill level. When over- or underfilled packages are detected, they can be automatically removed from the production line.
How can I monitor the performance of fill level inspection equipment?
Fill level inspection equipment tracks real-time data to monitor filling equipment performance and product fill levels. This data enables automatic adjustments to be made to the filling equipment to correct any filling issues during production. This means that if a filler dispenses too much or too little product, the system signals the filler to automatically adjust and correct the error without stopping production.
What are the effects of overfilling and underfilling in canned foods?
Over-filling canned foods can be costly as even minor errors can accumulate quickly. Underfilling canned foods can also be expensive as it can lead to dissatisfied customers and damage to your brand reputation. Additionally, it is crucial for canned foods to contain the specified amount of product as mandated by government regulations. If underfilled products are not detected before reaching store shelves, you may have to recall them and pay substantial fines.
Over- and underfill detection with the help of an in-line checkweighing solution makes it is easy to verify that cans have been properly filled.
