Detect and identify
Record the inspection result with a unique cycle or position. Define how multiple pouches between inspection and reject are tracked and how manual removal affects that sequence.
Line quality controls
Pouch coding, inspection and reject-system guide.
Define what is checked, where it is checked, how the individual pouch is tracked and what proves that a failed pack was removed.
Start with the quality decision, then select the device and line position.
A date coder, vision sensor, checkweigher or metal detector only creates value when the project defines the required decision, product/pack conditions, reject response and retained evidence. The line must preserve the identity of the affected pouch from detection to removal.
| Quality control | Define before selection | Integration questions |
|---|---|---|
| Date, batch or variable code | Content, character size, substrate, location, orientation, speed and permanence requirement. | Printer position, trigger, encoder, message control, consumables and code-area clearance. |
| Code verification | Presence only, legibility, correct content or full character recognition. | Lighting, contrast, camera field, reject decision and management of recipe/message changes. |
| Fill verification | Target, tolerance, sampling versus 100% check and action for out-of-limit packs. | Checkweigher or other method, conveyor stability, pack spacing, reject and data output. |
| Contaminant detection | Product/pack effect, test pieces, sensitivity target and validation routine. | Detector aperture, product effect, conveyor, reject, confirmation and failed-test response. |
| Seal/pack inspection | Defects to detect, limitations and required response. | Sensor/camera location, presentation, false reject control and manual verification. |
Specify pouch tracking and reject confirmation.
The control design should explain how a failed pouch is associated with its reject command and what happens if position tracking is lost or removal is not confirmed.
Reject and confirm
Choose a reject method suited to pouch weight, speed and conveyor presentation. Where the quality plan requires it, confirm that the reject occurred and that the pouch entered a secure reject location.
Fail safely
Define the response to a full reject bin, missing confirmation, detector fault, printer fault, camera fault or loss of tracking. The line may need to stop and control all unverified pouches.
Keep coding clear of the seal and variable pack geometry.
Code position should be shown on the pouch or film drawing. Avoid gusset folds, zipper/spout features, heavily textured areas and seal zones unless the selected coding and inspection method has been validated there.
For VFFS, account for print repeat, registration and the relationship between coder trigger and cut position. For premade pouches, control pouch orientation and presentation so the intended face and code area are consistent.
Use the material guide for substrate information and the seal guide to prevent code placement from compromising the pack.
Inspection and reject schedule
- Control name and quality decision
- Device and line position
- Trigger and product/pouch presentation
- Recipe or message ownership
- Pass/fail logic and limitations
- Pouch tracking method
- Reject mechanism and confirmation
- Reject-bin security and full condition
- Challenge/test routine and records
- Response to device or tracking fault
Include the complete quality chain in FAT and restart testing.
Challenge each failure mode with agreed test materials or simulated signals, verify the correct pouch is removed, confirm the fault response and check how the line restarts. Record both successful rejects and any pouches whose status becomes uncertain.
Automatic sequence and recovery are covered further on the automatic pouch filling machine page. Use the troubleshooting guide when a code, inspection or reject fault is intermittent.
Coding, inspection and reject questions.
Is a date coder the same as code verification?
No. The coder applies information; verification checks some defined property of that code. Presence, readability and correct content are different inspection levels.
Why is reject confirmation important?
A reject command does not prove that the pouch left the accepted product stream. Confirmation can be required where the quality plan needs evidence of physical removal.
What happens if tracking is lost?
The control philosophy should identify all pouches whose status is uncertain, prevent their release and define a controlled clearance and restart procedure.
Should checkweighing be included in the pouch filler speed?
Saleable output should include the actual conveyors, spacing, coding, inspection, reject and downstream conditions. An isolated filler cycle does not represent the complete line.
Who owns code-message changes?
The project should define authorised users, recipe/message control, line clearance, first-off verification and records so a correct mechanical setup cannot run with incorrect variable information.
Send the code drawing and quality-control schedule.
Include the pack artwork, required decisions, device interfaces and reject response so the complete line can be reviewed.