Start-up loss
Priming, air removal, first-off adjustment and packs produced before the process is stable.
Product recovery
How do you reduce product waste during paste filling?
Reduce paste filling waste by measuring where product is retained or rejected during start-up, normal running, stops, end-of-batch recovery and cleaning. A shorter, accessible product path and controlled restart can be more valuable than a faster cycle for short or high-value batches.
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Loss map
Separate retained product from rejected packs and cleaning loss.
Waste has different causes and remedies. Product left in a hose needs a different solution from packs rejected because of drips or an unstable restart.
Running loss
Drips, tails, underfill, overfill, misaligned containers and minor-stop rejects.
End-of-batch hold-up
Product retained in the hopper, valves, cylinder, pump, hose, manifold and nozzle.
Changeover loss
Product displaced or washed out, contaminated recovery and first packs after restart.
Buyer question
Where is product normally lost in a paste filling process?
Common loss points are hopper walls, valve pockets, cylinder or pump clearances, hoses, manifolds, nozzles, drips between packs and rejected start-up or restart containers. The largest loss depends on batch size, product value, path volume and how often the machine changes product.
Create a mass or volume balance for a representative batch: product issued, accepted packed product, recoverable residue, rejected packs and cleaning waste.
Buyer question
How does wetted-path volume affect recovery?
Every additional hose, manifold, chamber and fitting can retain product or require flushing. A larger path may be necessary for output or product supply, but its hold-up should be known and accessible.
For short runs, compare retained product as a proportion of the batch. Include the product trapped after a normal stop, not only what drains under ideal dismantling.
Buyer question
Can faster filling increase product waste?
Yes. Higher speed can increase splashing, tails, pressure, aeration, container instability and rejects if the nozzle, pack or downstream line cannot accept the profile. The useful target is accepted packs per hour at the agreed quality, not maximum discharge speed.
Record rejects and recovery time at each tested speed. A slightly slower stable profile may deliver more saleable product over the shift.
Buyer question
How should start-up and end-of-batch losses be measured?
Define the start and end points, weigh or measure product issued, identify accepted packs and keep rejected or recovered product separate. Record product remaining in each removable part and what can be returned safely under the site’s quality rules.
Repeat the method after a realistic stop and changeover so the number reflects production, not a specially prepared demonstration.
Buyer question
When is a dedicated product path justified?
A dedicated wetted set or machine route may be justified where cross-contact, curing, staining, incompatible cleaning, high product value or frequent changeover makes shared equipment costly or risky.
Compare the cost and control of dedicated parts with the time, waste and evidence needed to clean and restart a shared path. The decision should be based on the actual product family and production schedule.
Related questions and guides
Continue the specification with the next practical decision.
Use the related pages to connect this answer to product trials, machine selection and a quotation-ready application.
Cleaning and changeover
Map residue, strip-down and restart.
Read the guide →Nozzle cut-off
Reduce tails and delayed drips.
Read the guide →Multi-product flexibility
Assess when shared equipment remains practical.
Read the guide →Need to reduce paste filling loss?
Send the batch size, product value, current reject causes, cleaning method and photographs of product left in the system so the main loss points can be prioritised.