Reduce Product Non-Uniformity

Your Partner for Particles
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.

Non-uniform particle attrition

Particle attrition caused form pneumatic conveying.

Inspecting grain for non-uniformity

Inspecting grain for non-uniformity.

A tabletting press

A tabletting press

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

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.

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.

Funnel flow of cohesive material

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

Mass flow discharge pattern

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:

  • Particle segregation
  • Bulk density variability
  • Hygroscopic properties
  • Attrition or friability
  • Poor process control
  • Variable environmental conditions
Product non-uniformity in coffee beans
Jenike & Johanson engineer
Jenike & Johanson engineer

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