Line Trial Report: New Bottle Design

Pack Size Real Honey BOGO 500g

Trial location Foodcoast International (Honey Line)
Trial Date 20th February 2024
CPDD DRDC Unit QA/ Corp. QA Production/Section Ic.
Team Members Mr. Shubham Kumar Srivastava (CQA)
Mr. Pushkar Gupta Mr. Anil Thakur Mr. Ankit
Mr. Harsh (Foodcoast)

Packaging Material Analysis Report (If case of any deviation)

Note: Cavity wise materials shall be checked before Line Trial.

Deviation in cavities (If any) Specifications Actual Values Remarks

Multilayered Bottles

PP Caps

Environmental Condition of Shop Floor:

 Adequate light present at shop floor.
 Cleaning done before the trial.
 No off-odor found in the line.
 GMP maintained throughout the trial.
 Line Trial Report: New Bottle Design

Pre-condition before Line Trial

Machine & Accessories (Ok/ Not Ok) Remarks

Bottle Feeding Conveyer Ok Manual bottle feeding.
Bottle filling platform (Linear / Rotatory) Ok Linear bottle filling platform.
 Automatic filler- Two linear nozzles available but need to change
nozzle to fill PP bottles of this diameter.
Filling Nozzles (Linear / Rotatory) Not Ok
 Semi automatic filler- Single nozzle filling using foot operated
paddle.
Pneumatic / Hydraulic system for filling Ok Pneumatic filling system.
Cap conveyer system NA Not available.
Capping Machine NA Capping manually done by the workers.
Bottles from filling conveyor have to be placed for capping (manual)
Filled bottles conveyer system Not Ok
followed by placing it in induction sealing conveyor manually.
Single side at a time. Need modification in m/c for parallel
Labeling m/c Not Ok
application.
Sleeving m/c (if PVC sleeve over bottle ) NA Not applicable.
Need some parts change in shrink tunnel conveyor to minimize
Shrink tunnel (bundling to be done ) Not Ok
deviations like wrinkles, over-shrink

Line Trial
Note: Optimum speed shall be taken into consideration at the time of line trial

Machine & Accessories Speed (BPM) Observation & Remarks (if any)
Bottle Feeding Conveyer - Manually done by workers.
Linear filling nozzles in automatic filler but need to change nozzle to fit
Filling Nozzles (Linear / Rotatory) -
properly in this particular PP bottle.
Capping Machine - Capping manually done by workers.
Filled bottles manually transferred for capping then same was placed in
Filled bottles conveyer -
induction sealing conveyor.
Labeling / sleeving m/c 20 BPM Single side labeling at a time.
 Line Trial Report: New Bottle Design

Terminal Inspection (FG)

No. of
Parameter of Total bottles % of
defective Critical Major Minor Defects details
Inspection produced defects
bottles
Leakage 780 0
Filling Volume 780 0
Capping issue 780 0
Deformity in packs 780 0
Labelling/ sleeving issue 780 18 6 0.77 Label shifting
Scratches on bottles 780 0
Scratches on Caps 780 0
Product smearing 780 0
Shrink wrapping 780 12 7 0.9 Wrinkles

*100% Bottles shall be checked at the time of terminal inspection

Inference:
1. Automatic filling didn’t work out as filler needs nozzles with smaller dia. to fit inside the bottle head.
2. Filling with semi-automatic (foot operated) filler consumes more time and would not be feasible for higher volumes.
3. Labeling m/c is not suitable for parallel application of labels on both sides and frequent label shifting was observed.
4. Shrink tunnel conveyor need modification as current facility showed instability in wrapping.
5. Net quantity found okay.
6. No issues found in coding.
7. No leakages found.

Note: Transit trial shall be done with adequate no. of CFB’s, both for shorter & longer distance.