Filling tests

The purpose of filling tests behavior of a product when it is packaged in a container , whether it is bottles, tubes, sachets, cans, jars or any other type of industrial packaging.
These tests make it possible to check the fluidity, stability, foaming and reproducibility of the filled volume , in order to ensure the conformity of the packaging process and the final quality of the product.

The filling study is a key step in the design and industrialization of a product , because it directly impacts productivity, dosage accuracy and customer satisfaction .
It is particularly crucial for cosmetic, food, pharmaceutical and technical products , where viscosity, surface tension or sensitivity to air can influence the quality of the filling.

Methodology and parameters studied

Filling tests are based on mechanical and physical tests simulating real packaging conditions.
The parameters analyzed vary depending on the type of product and the process used (gravimetric, volumetric, vacuum or pressure filling).

The main aspects assessed are:

• The fluidity and viscosity of the product (sometimes measured by rheometry or powder cohesion analysis ).
• Foaming and degassing during filling, especially for air-sensitive liquids and gels.
• The stability of the product in the container after filling (phase separation, precipitation, sedimentation).
• The exact volume delivered and reproducibility between multiple cycles.
• Container-product compatibility , often studied via the stability and compatibility test .

These tests can be carried out under normal or accelerated conditions, depending on industrial or regulatory validation needs.

Matrices and application areas

Filling tests cover a wide variety of products, including:

• Cosmetic products : creams, lotions, gels, oils, hair products.
• Food and beverage products : juices, sauces, milks, liquid or semi-solid preparations.
• Technical and industrial products : paints, solvents, lubricants, glues, detergents, liquid polymers.
• Pharmaceutical and nutraceutical products : syrups, oral solutions, suspensions, encapsulated flowable powders.

These analyses make it possible to secure the packaging phase , to avoid problems with air bubbles, overflow or non-filling , and to guarantee the conformity of the volumes declared on the labels.

Industrial and regulatory applications

Filling tests are essential for:

• Validate the product's compatibility with packaging equipment (pumps, nozzles, capsules, dosing systems).
• Optimize production lines by reducing material losses and downtime due to filling defects.
• Check the quality of the final packaging (absence of leaks, correct sealing, homogeneity of the contents).
• Meet regulatory requirements for labeling, nominal quantity and packaging safety.

These tests are often part of a broader approach to evaluating product stability , including:

• The accelerated stability test .
• Analysis of the permeability of packaging materials .

Interpretation of results

The results of the filling tests allow the optimal packaging parameters (temperature, speed, pressure, ideal viscosity) to be defined and formulations to be adapted if necessary.
The data from the tests can also be integrated into the technical compliance files to justify the robustness of the product and the packaging process.

If instability occurs, additional tests such as surface tension measurement or bulk density analysis may be recommended to identify the cause of the problem.

YesWeLab expertise

YesWeLab provides you with a network of ISO 17025 and COFRAC accredited partner laboratories , specializing in mechanical, physicochemical and packaging testing .
Our experts support you in:

• Selecting the right test conditions for your product and packaging line.
• Interpretation of results and adjustment of formulation parameters .
• Validation of container-product compatibility before industrial launch.

Thanks to the YesWeLab digital platform , you can easily centralize your test requests , track your samples and access your analysis reports online.

For any specific request, contact our scientific team to define a tailor-made testing protocol adapted to your product and your packaging requirements.