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How Fill Level Losses Compound
Fill levels can be difficult to control in the food and beverage industry. Fast moving production lines need regular adjustments to keep fill levels accurate. If this is undertaken manually, the approach is more often reactive than proactive. Such a practice can lead to unscheduled downtime and loss of production, not to mention wasted product.
Underfilled products should never leave the production line for a number of reasons. Not only can underfilled products result in consumer dissatisfaction, it can even get your company into hot water with legal issues relating to weights and measures regulations set by the Food & Drug Administration. For instance, if your product label reads a net weight of 8 oz., it must contain at least 8 oz. of actual product; anything less is considered unlawful and can result in product recalls or further action by the FDA. For more info on net quantity requirements, see Title 21 CFR 101.7.
Overfilled products are also problematic on multiple fronts. If the excess product fits into the container, manufacturers are essentially giving product away, but the keyword there is “if”. Overfilled products can compromise their containers; at best, creating a mess that might lead production to a halt, and at worst destroying the integrity of the container or its seal, resulting in unprecedented health and safety hazards.
Over the course of a high speed production run, fill level-related issues can soon mount and, when extended over weeks, months, and years, can result in substantial losses.
How X-Ray Simplifies Fill Level Inspection, And More
Advanced x-ray systems are becoming widespread in the food and beverage industries due to their extended capabilities. Unlike more traditional inspection equipment such as metal detectors, x-ray inspection machines can detect contaminants within a variety of container materials including bone, metal, glass, and plastic. In addition to offering superior contaminant detection, they feature a number of other quality control checks that can be carried out simultaneously.
Automated Fill Level Inspection
One such feature is fill level inspection and control. Manufacturers can set minimum and maximum fill level parameters, and products falling outside of this range will be automatically rejected from the line. In addition, it is now possible to eliminate operator involvement by enabling the x-ray system to automatically feed back to the filling machine, a feature that is particularly beneficial when processing liquid foods and beverages. Automatic adjustments can be made while the line is still fully operational, keeping downtime, waste, and human interaction with the line to an absolute minimum.
Do More Than Just Checkweighing
Zoned fill level inspection checks for products such as ready meals are also possible with x-ray systems, something that is not possible with a checkweigher. Component counts using zonal inspection can be undertaken without the need for average weight calculations.
A checkweigher can only convert total weight into individual counts if the average piece weight is known, and even that approach leaves room for error. These additional benefits make x-ray systems a more complete product inspection solution with combined quality check and contaminant detection capabilities.
Discover all that x-ray inspection has to offer, from superior contaminant detection to fill level verification and everything in between. EXPLORE X-RAY CAPABILITIES >>>
Fill Level Inspection Doesn’t Mean Slowing Down
An x-ray systems’ ability to carry out these inspection tasks inline means that line speeds are never affected by the inspection process. Where manual inspection creates a production bottleneck and potential safety hazards for personnel, x-ray systems facilitate seamless fill level checks without disrupting the production line or bringing personnel into close contact with high-speed machinery. One hundred percent of products can pass through the system and manufacturers can be assured that the products continuing downstream are contaminant free and filled to the correct level.
Wasted product is equal to wasted dollar bills, and by investing in advanced product inspection systems, the potential savings can produce a rapid return on investment and a more consistent, higher-quality offering.
Eagle’s In-Line Fill Level Inspection Solutions
Eagle offers the food industry’s most advanced inspection solutions that are capable of simultaneous contaminant detection and quality checks including fill level, mass measurement, package integrity, and more. These are Eagle systems that have been engineered with fill level as a key quality inspection capability
Tall PRO X
This larger inspection machine provides technical capabilities and precise contaminant detection and has a greater than 30% increase in conveyor capacity, Tall PRO X helps inspect more product at high production speeds.
Tall PRO XS
The Tall PRO XS isis a mid-range solution, ideal for production lines with limited space. It provides full inspection of upright containers running at line rates in excess of 1000 PPM.
Tall PRO XSDV
Tall PRO XSDV. equipped with a dual view technology provides consistent fill level inspection and enhanced contaminant detection. With a compact footprint, it installs over existing conveyor lines for easy integration.
QuadView
Our most advanced system that’s purpose-built for inspecting jars, bottles, and other upright containers, QuadView provides full 4-view visibility of your product to ensure fill level and uniformity.
Want to compare options? Eagle PI can help you discover the right x-ray system for your quality inspection needs. CONTACT US >>>
FAQs of
Fill Level Inspection with X-ray Systems
What is fill level inspection in food manufacturing?
Fill level inspection is the process of verifying that packaged food and beverage products meet defined minimum and maximum fill levels. It helps ensure compliance with regulations, maintain product quality, and prevent costly overfill and underfill losses on production lines.
How do x-ray systems perform fill level inspection?
X-ray systems perform fill level inspection by analyzing density differences within a package to accurately measure product levels. These systems can automatically detect underfilled or overfilled products in real time and reject them from the line without slowing production.
Why is automated fill level inspection important?
Automated fill level inspection reduces product waste, prevents regulatory issues, and improves production efficiency. By eliminating manual checks and enabling real-time adjustments, manufacturers can maintain consistent fill levels and avoid costly downtime.
What are the benefits of x-ray fill level inspection vs checkweighing?
X-ray fill level inspection provides more precise and versatile quality control. In addition to verifying fill levels, x-ray systems can inspect how the contents are positioned within the container, such as identifying uneven settling, voids, clumping, or off-center placement, detect contaminants, and perform zoned inspections that checkweighers cannot achieve.
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