Key decisions
Use the trial to answer defined engineering questions
- Send production-representative product, containers and closures with known storage and preparation history.
- Include the smallest and largest dose, narrowest opening, least stable pack and hardest product condition.
- Agree observations and measurements before the run so the result cannot be selected afterwards.
- Record machine settings, product temperature, feed arrangement, operator actions, rejects and open items.
- Retain approved samples, images and the signed record as controlled project evidence.
Define the uncertainty before selecting samples
Start by listing what is not yet known. Typical questions include whether the product can be primed reliably, whether particles pass through the product path, whether foam can settle inside the available headspace, whether a stringing paste can cut off cleanly, whether a powder bridges, and whether the pack remains stable during nozzle entry and transfer.
Rank the questions by impact. A risk that could change the dosing principle or machine architecture should be tested before lower-impact settings optimisation. The technology comparison helps identify which alternative routes should remain available during the trial.
| Trial input | Representative evidence | Avoid |
|---|---|---|
| Product | Normal production batch plus known difficult variation, supplied in enough quantity for priming and sustained running. | A substitute with different viscosity, density, particles, foam or temperature behaviour. |
| Containers | Production packs including smallest opening, least stable base and credible dimensional variation. | One hand-selected container that has not passed through normal storage or handling. |
| Closures and labels | Real components where they affect headspace, fill level, drips, transfer or downstream handling. | Assuming the filling result is independent of closing and presentation. |
| Dose range | Minimum, normal and maximum commercial quantities. | Testing only the middle of a wide range. |
| Process states | Start-up, normal run, refill, pause, restart and changeover where relevant. | A short uninterrupted sequence from a full hopper. |
| Measurement | Agreed quantity and quality method with sequential records. | Selecting only the best packs after the trial. |
Supply enough material to expose normal operation
The trial quantity must cover priming, adjustments, representative running, measurement samples, cleaning observations and reasonable loss. A very small sample may prove that product can pass through a nozzle but cannot show replenishment behaviour, temperature drift, air entrainment or sustained pack handling.
Record how the product was manufactured, stored, mixed and brought to the trial. For temperature-sensitive or settling products, this history can be as important as the commercial name. Safety data and handling controls should accompany chemical products where applicable.
Observe pack quality as well as quantity
A measured dose can still be unacceptable if the neck is contaminated, the product tails across the container, foam obscures the intended headspace, powder dust prevents sealing or the pack deforms during handling. Define the finished-pack checks that matter to capping, sealing, labelling, coding and inspection.
Photograph representative acceptable and unacceptable results. Where the product or pack creates a recurring defect, record the machine change and the effect rather than continuing until one good pack appears. This creates evidence for nozzle selection, container support and downstream interfaces.
Use a controlled trial record
The record should identify machine, tooling, software recipe, product batch, containers, date, operators and measurement equipment. Capture settings that influence the result, including feed pressure, hopper level, speeds, nozzle height and any suck-back or fine-feed adjustment. Note every manual intervention.
Classify each conclusion as proved, conditionally acceptable, not proved or not tested. Assign actions and owners to open points. This prevents a promising demonstration from being treated as complete validation and gives the quotation team a reliable basis for inclusions and qualifications.
Carry approved evidence into the project
Retain approved filled packs where practical, or controlled photographs and measurements where storage is unsuitable. The supplier and buyer should agree which product and pack versions form the reference. If the formulation or container changes, the impact should be reviewed before FAT.
Use the same acceptance language in the quotation, FAT and SAT protocol and handover record. A clear evidence chain reduces late disputes and makes necessary site-specific confirmation visible.
Product trial pack to send
- Product samples with batch, preparation and storage information.
- Safety data and handling instructions where applicable.
- All required containers, closures and relevant labels.
- Dose range, tolerance and quality acceptance method.
- Expected batch size and sustainable output requirement.
- Bulk product feed and replenishment description.
- Cleaning, recovery and cross-contamination expectations.
- Named questions the trial must answer and open risks to record.