How a High-Precision Dynamic Checkweigher Improved Weight Accuracy for 10g–100g Seasoning Powder Packaging
A Real Production Line Case Study from Shanghai Fanchi-tech Machinery Co., Ltd.
As global demand for seasoning powders continues to grow, manufacturers are under increasing pressure to deliver consistent package weights while reducing production costs. Whether supplying supermarket private labels, foodservice distributors, or seasoning brands, maintaining accurate net weight has become just as important as ensuring product quality.
For lightweight products such as 10g, 20g, 50g and 100g seasoning powder sachets, even a deviation of 0.3–0.5g can lead to significant product giveaway or underweight packages. This directly impacts production costs, customer satisfaction, and compliance with international regulations.
To address these challenges, one Southeast Asian seasoning manufacturer upgraded its packaging line with a Fanchi High-Precision Dynamic Checkweigher, achieving higher production efficiency, improved weight consistency, and reduced product waste.
Customer Background
The customer is a professional seasoning manufacturer supplying OEM and private-label products to supermarkets and food companies in Europe, the Middle East, and Southeast Asia.
Their main products include:
- Chicken Seasoning Powder
- Curry Powder
- Chili Powder
- Garlic Powder
- White Pepper Powder
- Black Pepper Powder
- BBQ Seasoning
- Instant Soup Mix
The factory operates two fully automatic packaging lines producing approximately 100–120 pouches per minute.
Typical package sizes include:
| Product | Package Weight |
|---|---|
| Chicken Powder | 10 g |
| Garlic Powder | 20 g |
| Curry Powder | 50 g |
| BBQ Seasoning | 80 g |
| Mixed Spice | 100 g |
| Soup Powder | 200 g |
These lightweight products fall perfectly within the optimal weighing range of the Fanchi Dynamic Checkweigher (3–300 g).
Production Challenges Before Installing the Checkweigher
Although the customer had already invested in modern auger filling machines, several issues remained.
Challenge 1 – Filling Accuracy Changed During Production
The seasoning powders had different bulk densities and flow characteristics. During long production runs, vibration, humidity, and material settling caused slight variations in filling accuracy.
As a result, package weights gradually drifted outside the customer's preferred tolerance.
Challenge 2 – Excessive Product Giveaway
To prevent underweight complaints, operators intentionally increased the filling target.
For example:
Target Weight
50 g
Actual Filling
50.8–51.2 g
This meant every package contained approximately 0.8–1.2 g of unnecessary product.
Although almost invisible on a single pouch, the accumulated loss became substantial over millions of packages.
The factory estimated that thousands of kilograms of seasoning powder were being given away every year.
Challenge 3 – Manual Sampling Could Not Detect Every Defect
Previously, quality inspectors randomly checked package weight every 30 minutes.
This meant that hundreds or even thousands of pouches could pass through the line before a filling issue was discovered.
Challenge 4 – Export Customers Requested Complete Inspection Records
Several European customers required documented evidence that every production batch complied with declared net weight.
Manual inspection records were no longer sufficient to satisfy modern food safety audits.
Fanchi Engineering Evaluation
After reviewing the customer's production line, Fanchi engineers proposed installing a compact high-precision dynamic checkweigher immediately after the VFFS packaging machine and before the metal detector.
This location allows every finished pouch to be weighed automatically before entering the final quality inspection stage.
The compact footprint fit perfectly into the customer's existing production line without requiring major modifications.
Why This Checkweigher Was Selected
Unlike large-package checkweighers designed for cartons or bags weighing several kilograms, this model is specifically engineered for lightweight flexible pouches.
Its weighing platform and conveyor dimensions are optimized for products between 3 g and 300 g, making it particularly suitable for seasoning powder packaging.
The system combines high weighing accuracy with high-speed operation, allowing manufacturers to inspect every pouch without reducing production throughput.
How the Checkweigher Works on the Packaging Line
Once each pouch leaves the vertical packaging machine, it enters the Fanchi checkweigher.
Step 1 – Product Spacing
The infeed conveyor automatically separates each pouch, ensuring stable weighing conditions.
Even lightweight 10 g sachets remain properly aligned while travelling along the conveyor.
Step 2 – Dynamic Weighing
Each pouch passes smoothly across the precision weighing platform.
Within milliseconds, the high-speed load cell measures the exact package weight.
The intelligent controller compares the measured weight with the preset target value and acceptable tolerance.
For example:
Target Weight:
50.0 g
Acceptable Range:
49.7–50.3 g
Every package is inspected individually without stopping production.
Step 3 – Automatic Decision
If a pouch falls outside the specified weight range, the controller immediately sends a reject signal.
Depending on the customer's production requirements, the system can be equipped with:
- Air Blast Reject
- Pusher Reject
- Swing Arm Reject
- Drop Flap Reject
Only qualified products continue to the metal detector and final packing station.
Step 4 – Production Data Recording
During production, the touchscreen continuously displays:
- Current Package Weight
- Average Weight
- Production Quantity
- Pass Rate
- Reject Count
- Weight Distribution
- Alarm History
This data helps quality managers monitor production performance in real time.
Results After Installation
Within several weeks of operation, the customer reported measurable improvements.
Product Giveaway Reduced
By tightening filling control, average product giveaway was reduced by approximately 26%.
This generated significant annual savings in seasoning powder consumption.
Improved Weight Consistency
More than 99.5% of finished pouches remained within the customer's specified tolerance.
Reduced Quality Complaints
Automatic inspection eliminated the risk of underweight products reaching customers.
Increased Production Efficiency
Operators no longer needed to interrupt production for frequent manual sampling.
Quality inspection became fully automated.
Better Traceability
Electronic production records simplified customer audits and supported export documentation requirements.
Why More Seasoning Manufacturers Choose Fanchi
Modern seasoning production requires more than accurate filling.
Manufacturers increasingly demand complete inline inspection solutions that improve efficiency while ensuring food safety.
Fanchi provides integrated inspection systems including:
- Dynamic Checkweighers
- Metal Detectors
- X-ray Inspection Systems
- Combined Metal Detector & Checkweigher Solutions
These systems can be customized according to production speed, product size, and factory layout.
Typical Applications
The Fanchi Dynamic Checkweigher is ideal for lightweight packaged food products, including:
- Chicken Seasoning Powder
- Curry Powder
- Garlic Powder
- Onion Powder
- Chili Powder
- Black Pepper Powder
- White Pepper Powder
- Mixed Spice
- Soup Powder
- Instant Coffee Sachets
- Milk Tea Powder
- Matcha Powder
- Cocoa Powder
- Sugar Sachets
- Salt Sachets
- Baking Powder
- Protein Powder Sachets
Recommended Product Weight: 3 g – 300 g
Frequently Asked Questions
Can this machine accurately inspect small 10 g seasoning sachets?
Yes. The weighing platform and high-speed load cell are specifically optimized for lightweight products between 3 g and 300 g, ensuring stable and reliable inspection.
Can it be connected to our existing VFFS packaging machine?
Absolutely. The compact conveyor design allows seamless integration with most vertical packaging machines without major modifications.
Can one machine inspect different pouch sizes?
Yes. Operators can store multiple product recipes and quickly switch between 10 g, 20 g, 50 g, 100 g, and 200 g packages using the touchscreen interface.
Can it work together with a metal detector?
Yes. Many customers install the Fanchi Dynamic Checkweigher directly before a Fanchi Metal Detector to create a complete inline quality inspection system.
Partner with Shanghai Fanchi-tech Machinery Co., Ltd.
At Shanghai Fanchi-tech Machinery Co., Ltd., we specialize in providing reliable inspection equipment for the global food industry. From lightweight seasoning sachets to complete packaging lines, our engineering team delivers customized solutions that improve product quality, reduce waste, and support export compliance.
Contact: Kerry
Email: kerry@fanchitech.net
Mobile / WhatsApp: +86 13917555254
Website: www.fanchitech.net
YouTube: https://youtube.com/@fanchitech3323?si=gyh-f9JCbjkJ3tEu
Post time: Jul-13-2026