Target fill
The intended net quantity set for the product and pack.
Performance specification
Automatic filling machine accuracy, repeatability and real production output
Define how results will be measured before comparing percentage claims, nozzle counts or catalogue speeds.
- Accuracy versus repeatability
- Sustained line output
- FAT and SAT criteria
Measurement terms
Use consistent definitions in every quotation
Ambiguous performance language makes otherwise similar proposals impossible to compare.
Accuracy
How close measured results are to the agreed target after calibration.
Repeatability
How tightly repeated fills group under stable conditions.
Resolution
The smallest controllable or displayed increment, which is not the same as achieved accuracy.
Throughput
The number of acceptable containers produced in a stated period.
Line efficiency
Actual production compared with theoretical production during planned running time.
Accuracy drivers
What changes the delivered dose
The dosing system is only one source of variation.
- Product temperature and viscosity
- Air in the product or inconsistent feed pressure
- Seal, valve, pump and nozzle condition
- Cylinder or pump operating range
- Foam, drip and product retained at the nozzle
- Container tare and measurement method
- Machine speed and motion profile
- Calibration procedure and operator adjustment
Output model
Build speed from the cycle, then test the complete line
Theoretical output is a useful starting point, not a production guarantee.
Indexed filler approximationOutput per minute ≈ heads × 60 ÷ cycle seconds
The cycle includes container index, settle, nozzle movement, filling, cut-off and release.
Shift output estimateGood packs ≈ speed × 60 × running hours × efficiency
Subtract planned changeovers, breaks and cleaning before applying line efficiency.
Use the calculator as a planning aid. Real output must be confirmed with the actual product, container and complete line.
Head-count decisions
More heads change product supply, cleaning and changeover
A nozzle bank needs balanced feed, head-by-head calibration and enough downstream capacity.
- Calculate fill time at the slowest product
- Confirm the hopper or pump can feed all heads
- Check container pitch and nozzle-spacing range
- Allow for cleaning a larger product manifold
- Confirm capper and labeller capacity
- Plan head-specific calibration and fault diagnosis
Acceptance test
Write FAT and SAT criteria before purchase
A measurable protocol protects both buyer and supplier.
| Test | Define in advance | Evidence |
|---|---|---|
| Fill result | Target, tolerance, sample size and measurement method | Recorded weights or volumes |
| Output | Product, dose, container, duration and acceptable stops | Accepted packs over timed run |
| Changeover | Start and finish state, tools and trained operator | Observed timed sequence |
| Reject logic | Faults to simulate and reject confirmation | Traceable test results |
| Cleaning | Demonstration scope and acceptance boundary | Procedure and inspection |
Practical answers
Filling accuracy and output FAQs
Answers are general guidance. Final suitability depends on product trials, containers and the confirmed machine specification.
What is the difference between filling accuracy and repeatability?
Repeatability describes how closely repeated fills agree with one another. Accuracy describes how close the result is to the intended target. A machine can be repeatable but incorrectly calibrated.
How should filling speed be quoted?
Use sustained containers per minute or hour with the actual product, dose and container, including the required fill profile and indexing method.
Does adding more nozzles always increase output?
Only if product supply, container handling, fill time and downstream equipment can support the additional heads.
How is machine performance accepted?
Agree the product, pack, sample size, test duration, output, tolerance, rejects and changeover conditions before FAT and SAT.
Continue your shortlist
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View optionsPerformance evidence
Turn accuracy and output into a reproducible acceptance test
Comparable performance needs a defined product, pack, instrument, sample method, run condition and record of rejects, stops and adjustments.
Separate measurement capability from production capability
Accuracy, repeatability and output should be tested as connected but distinct results. A filler may deliver repeatable doses during isolated cycles yet lose performance when product supply, container indexing, nozzle cut-off or downstream stops are introduced. The acceptance plan should therefore include static or short-run measurement checks and a sustained line run with normal interruptions recorded.
The reference method matters. A weight check can be practical, but it only represents volume when density is known and stable. A visual fill-level check answers a different question from a gravimetric or volumetric result. The test should state the reference instrument, calibration status, tare method, sample frequency and how rework or rejected packs are treated.
Use individual-head data on multi-head fillers. An overall average can hide a head that consistently runs high or low. Record the results in production order where possible so drift, refill events or pauses can be connected to the affected packs. Changes made during the test should be logged rather than silently resetting the sample.
Output should be reported as accepted packs over time. Note stops, rejects, product refill, container shortages and downstream blockage. This turns a headline rate into evidence that can be compared with the line design and the output calculator.
| Measure | Definition to agree | Test condition | Evidence to retain |
|---|---|---|---|
| Dose repeatability | Variation of repeated fills from the same head under stated conditions | Representative product, dose, container, stable feed and agreed sample size | Individual results, reference instrument, settings and any excluded samples |
| Head-to-head balance | Difference between parallel filling heads under the same cycle | All heads sampled before and after normal pause or product refill | Results by head, calibration changes and approved correction limits |
| Sustained output | Accepted packs produced during an agreed timed run | Complete line or defined test scope, normal product feed and downstream operation | Run time, accepted quantity, rejects, stop log and calculated rate |
| Reject performance | Ability to identify and remove packs defined as unacceptable | Deliberate safe challenges within the agreed inspection and tracking scope | Challenge type, detection, reject confirmation and line response |
| Changeover performance | Time and tasks from last accepted pack of one format to first accepted pack of the next | Defined starting/finishing state, identified parts, trained operator and line clearance | Task record, elapsed time, settings, first-off checks and issues |
| Product recovery/cleaning | Product retained and effort needed to reach the agreed clean state | Normal end-of-batch condition and agreed cleaning method | Recovered quantity where measured, task steps, verification and parts removed |
Machine-only test
Useful when the objective is to isolate filler dosing and container presentation. It must not be presented as proof of a complete-line output.
Integrated line test
Includes the connected stations and normal handshakes. Record which upstream and downstream equipment is represented or simulated.
Site production test
Confirms final utilities, product feed, installed interfaces and operator workflow. Site-dependent results should be closed separately from FAT.
Send your project details
Define the measurement plan before quotations are compared so accuracy and output claims use the same evidence.
Further buyer questions
More filling performance questions
Accepted output and head-by-head measurement should be recorded under a defined test condition.
Should rejected containers be included in an output test?
They should be recorded and handled according to the agreed acceptance rule. Report accepted packs, rejects and stop time separately so the useful production rate is not overstated.
Why should every filling head be measured separately?
An average across all heads can conceal a persistent high or low head. Individual results make calibration, feed imbalance and maintenance issues visible and support a clearer acceptance decision.
Make the result reproducible
Separate the filling process from the measurement process
A reported fill result is only comparable when product condition, reference instrument, tare, sample order, active head, machine state and calculation method are recorded.
| Evidence question | Why it matters | Related guide |
|---|---|---|
| Does variation follow every head or one head? | Common movement suggests product feed, temperature, air, recipe or measurement; one-head movement suggests a channel-specific path or setting. | Troubleshooting patterns |
| Does the result change at start, refill or restart? | A steady-state sample may hide priming, settlement, drain-down, pressure or temperature effects. | Representative trial sequence |
| Is the nominal machine rate usable by the complete line? | Capping, labelling, buffers, faults, changeovers and replenishment determine sustainable output. | Automatic bottle filling lines |
| Is the reference method suitable? | Container tare, evaporation, foam, temperature and instrument resolution can distort the conclusion. | Acceptance test planning |
Retain raw head-by-head data
Do not keep only an average. Record sample order and filling-head identity so drift, bias, start-up effects and intermittent channels remain visible. State any settings changed during the test and the point at which the formal sample began.
Define accuracy and output under stated conditions
Send the product, dose, pack, measuring method, required production window and line sequence. Lancing can help translate the target into a representative trial and acceptance protocol.