What causes fault code PKG-FILL1 (Filling Machine — Fill Level Out of Tolerance)?

Fill nozzle clogged or partially blocked — restricting flow on some fill heads. Product supply pressure or level fluctuating — inconsistent head pressure to the filler. Fill valve timing drift — solenoid valve response time changed due to wear. Product temperature changed — viscosity change affects flow rate at the same valve timing. Load cell or flow meter drift — fill measurement sensor needs recalibration

How do I fix fault code PKG-FILL1?

Spot-check fill weights on a bench scale — check 10 consecutive fills to assess variation. Clean all fill nozzles — remove and inspect for product buildup or obstructions. Check product supply pressure at the filler manifold — should be consistent within 2%. If volumetric filling, check product temperature — recalculate volume-to-weight conversion if temp changed. Calibrate the fill measurement system (load cells, flow meters) using certified test weights or volumes. If using time-based filling, check solenoid valve response — replace valve if slow to open or close

Filling Machine — Fill Level Out of Tolerance

PKG-FILL1

Filling machine is not achieving target fill weight or volume consistently. Products are overfilled or underfilled beyond the acceptable tolerance band.

medium packaging

packaging filler fill level weight volume nozzle calibration

Probable Causes (ranked)

Fill nozzle clogged or partially blocked — restricting flow on some fill heads
Product supply pressure or level fluctuating — inconsistent head pressure to the filler
Fill valve timing drift — solenoid valve response time changed due to wear
Product temperature changed — viscosity change affects flow rate at the same valve timing
Load cell or flow meter drift — fill measurement sensor needs recalibration

Fix Steps

1 Spot-check fill weights on a bench scale — check 10 consecutive fills to assess variation
2 Clean all fill nozzles — remove and inspect for product buildup or obstructions
3 Check product supply pressure at the filler manifold — should be consistent within 2%
4 If volumetric filling, check product temperature — recalculate volume-to-weight conversion if temp changed
5 Calibrate the fill measurement system (load cells, flow meters) using certified test weights or volumes
6 If using time-based filling, check solenoid valve response — replace valve if slow to open or close

Field Trick

Fillers that were accurate yesterday and are off today — check the product temperature first. A 10-degree temperature change on a viscous product changes the flow rate by 15-20%. Honey at 70F fills completely different than honey at 80F. If the product temp varies, you need temperature-compensated filling.

Suggested Replacement Parts

Parts matched to fault category: Solenoid Valve

SMC SY3120 Solenoid Valve P/N: SY3120-5LZD-M5 5/2 way, 24VDC, M5 ports, direct piping, 0.15-0.7 MPa

AutomationDirect $32.00 Amazon $28.00 McMaster-Carr $45.00 Grainger $42.00

Festo VUVG Solenoid Valve P/N: VUVG-LK14-M52-AT-G18-1R8L 5/2 way, 24VDC, G1/8 ports, spring return

AutomationDirect $55.00 Amazon $62.00 Grainger $70.00

Air Pressure Regulator + Filter Combo P/N: AW30-03BG SMC AW series, 3/8 NPT, 5-125 PSI, with gauge and bowl guard

AutomationDirect $38.00 Amazon $32.00 McMaster-Carr $48.00

Prices are estimates. Verify part numbers match your equipment before ordering.

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