Portion population
Review how many useful portions sit below and around the target. A poor population limits the combinations the controller can choose.
Understand the mechanism
The calculation can only select from the portions made available to it.
Feed trays move product into weigh hoppers. The controller then evaluates available portions and selects a combination for the target. If portions are consistently too large, too small, uneven or unavailable, the best possible combination may still create excess fill or slow the cycle.
Feed stability
Bulk-feed surges, starvation, changing product level or inconsistent vibration can alter portion size throughout the run.
Measurement method
Use a controlled sample of individual finished packs and record mean, minimum, maximum, variation, rejects and excess product.
Diagnostic sequence
Change one controlled factor at a time and retain the weight data.
Verify the check method
Confirm the reference scale, tare, sampling method and treatment of rejected or incomplete packs.
Check calibration and zero stability
Confirm the machine is stable and suitable for investigation before tuning product feed.
Review product distribution
Look for uneven loading, empty hoppers, overloaded hoppers, bridging or product build-up.
Review portion sizes
Adjust feed settings only with reference to the target, number of heads, product behaviour and cycle demand.
Run a sustained sample
Record weights, output, rejects, stoppages and refill events long enough to reveal production variation.
| Symptom | Possible area to investigate | Evidence |
|---|---|---|
| Stable but consistently high mean | Target setting, portion size, allowed combinations and pack/check method | Individual weights and portion statistics |
| Wide spread | Unstable feeding, product build-up, vibration, calibration or discharge loss | Trend by time and hopper behaviour |
| Low giveaway but slow output | Portions too small, insufficient available combinations or downstream waiting | Cycle states and waiting-time record |
| Good short run, poorer long run | Refill changes, product build-up, temperature or batch variation | Sustained run with events noted |
Acceptance criteria
Agree the product, sample size and performance calculation before the FAT.
Accuracy and giveaway must be tied to the target, product, configuration and test method. The trial and FAT guide explains how to record the evidence. No setting change should compromise legal, customer or pack-quality requirements.
Performance review
Send the weight data and the conditions under which it was collected.
Lancing can review the product, targets, existing results and line sequence to identify the next practical checks.
Discuss giveaway controlBuyer questions
Frequently asked questions about this application.
What is product giveaway?
Giveaway is product packed above the target or required minimum. It should be calculated from controlled finished-pack data.
Does a multihead weigher eliminate giveaway?
No. It can improve combination selection, but product behaviour, portions, settings, calibration and pack handling still affect the result.
Why can lower giveaway reduce output?
Very small portions or restrictive settings can make it harder to find a valid combination quickly. The balance must be proven for the real application.
How many packs should be tested?
The sample size should be agreed for the application and acceptance purpose. A short sample may not represent refill events or production variation.
Related guidance
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