Reduce Product Non-Uniformity | Product Non-Uniformity Solution

Overview

What is Product Non-Uniformity?

Product non-uniformity is used to describe situations in which a product does not meet quality-control metrics set by your company, your customers, or a regulatory agency.

It can mean a variety of different things for different industries. For example, tablets produced by a pharmaceutical company may not have the required mass or content uniformity. Or, a box of cereal flakes may contain too many fines or crumbs.

Particle attrition caused form pneumatic conveying.

Inspecting grain for non-uniformity.

A tabletting press

Vertical multi-head weigher packaging machine for chips to help ensure accurate dosing and uniformity.

Corn snacks passing through a tumbling machine to support product uniformity.

Challenge

Why is Product Non-Uniformity a Problem?

Product Non-Uniformity can result in:

Customer complaints
Rejected product or recalls
Process inefficiency
Poor quality control
Erratic dosage weight, mass
Variable particle size
Excess waste or rework
Caking or agglomeration
Poor product appearance
Damaged reputation

Caking of a product due to product non-uniformity

Product non-uniformity can lead to caking of certain materials.

A hopper flow obstruction due to a rathole within the material

Ratholing due to product non-uniformity hinders free material flow.

Product non-uniformity can lead to funnel flow, where one portion of the material moves while the other remains still.

Mass flow ensures that all the material in a silo moves during withdrawal, eliminating ratholing and stagnant zones.

Factors

When & Where Can Product Non-Uniformity Occur?

Non-uniform product can be produced in the form of bags, packages, unit doses (e.g., tablets, capsules), batches, and sacks. Poor flow and process variability can readily contribute to production of poor quality material.

Flow through material handling equipment such as silos, hoppers, feeders, transfer chutes, pneumatic conveying systems, and mechanical conveyors can generate product variability, as well as maintain uniformity, if done properly.

Non-uniform products can be the result of: