Filling tests

Fill tests aim to evaluate a product's behavior when packaged in a container , whether it be bottles, tubes, sachets, cans, jars, or any other type of industrial packaging.
These tests verify the flowability, stability, foaming, and reproducibility of the filled volume , ensuring the conformity of the packaging process and the final product quality.

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

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.
• Product stability in the container after filling (phase separation, precipitation, sedimentation).
• The exact volume delivered and reproducibility between several cycles.
• Container-product compatibility , often studied via stability and compatibility testing .

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

Matrices and application domains

Filling tests are relevant to 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 fluid powders.

These analyses help to secure the conditioning phase , to avoid problems of 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 the packaging equipment (pumps, nozzles, capsules, dosing systems).
• Optimize production lines by reducing material losses and stoppages related to filling defects.
• Check the quality of the final packaging (no leaks, correct sealing, homogeneity of contents).
• Meet regulatory requirements regarding labelling, nominal quantity and packaging security.

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 the results

The results of the filling tests allow for the definition of optimal packaging parameters (temperature, speed, pressure, ideal viscosity) and the adaptation of formulations if necessary.
The test data can also be included in technical compliance documentation to demonstrate the robustness of the product and the packaging process.

In case of instability, further tests such as surface tension measurement or apparent density analysis may be recommended to identify the cause of the problem.

YesWeLab's expertise

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

• Selecting the test conditions that are appropriate for your product and your packaging line.
• Interpreting the results and adjusting the formulation parameters .
• Validation of container-product compatibility prior to 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 customized testing protocol adapted to your product and packaging requirements.