For this application, the customer required a fully automated solution for filling 400 ml containers at speeds of up to 200 bpm, combining high net weight accuracy, hygienic processing and reliable handling of yogurt with suspended fruit pieces. The system also needed to integrate into an existing production line while providing continuous quality control.
The challenge
The main challenge was to achieve consistent net weight accuracy with a non-homogeneous product containing fruit pieces, while maintaining the integrity of the particles throughout the filling process.
At high production speeds, variations in product flow and particle distribution can affect dosing repeatability. The filling system therefore needed to control the product gently while continuously monitoring the weight of each container and correcting any deviations in real time.
Hygiene was equally important. As a dairy application, the system had to be fully washable and designed to support effective drainage, cleaning and maintenance, while minimizing downtime.
The Weightpack solution
Weightpack proposed a fully washable rotary net weight filler equipped with 36 servo-assisted valves, IP69K load cells and a dedicated product handling system designed for drinking yogurt with fruit pieces.
The yogurt is fed through a tankless line by a volumetric pump and distributed to the rotary manifold under controlled pressure. Each container is weighed before, during and after filling using dedicated load cells. The PLC continuously processes the weight data, allowing the machine to identify deviations and automatically correct the dosing in real time.
Weightpack's patented dosing valve combines an auger with a pneumatic pinch valve. This configuration allows the system to handle yogurt containing fruit pieces in a controlled and repeatable way, helping preserve the integrity of the fruit while maintaining accurate dosing.
Key features include:
- Net weight filling with real-time automatic correction
- Gravity-assisted dosing system with auger
- Filling accuracy up to ±0.5 g, even with non-homogeneous products
- Sloped frame for complete drainage and hygienic cleaning
- COP/CIP/SIP-compatible components
- AISI 316/304 stainless steel structure with CE-compliant guards
- Automatic rejection of out-of-tolerance containers
- Tool-free openable design for faster format changes and maintenance
Performance in production
The solution combines accurate weight control with gentle product handling, addressing two of the key requirements when filling drinking yogurt with fruit pieces.
Real-time correction helps maintain consistent filling weights and reduce product giveaway, while the dedicated dosing system supports repeatable handling of the fruit pieces. The fully washable, sloped machine design also facilitates drainage and cleaning, supporting the hygiene requirements of dairy production.
The result is a high-speed filling solution that brings together precision, product care and hygienic performance, helping the customer improve filling consistency, reduce waste and minimize production stops while maintaining reliable operation at up to 200 bpm.