Auger Filling & Testing Guide

Purpose and Use

This guideline supports auger filling and auger tooling training and provides a shared baseline of tooling concepts, product behavior, and testing practices and is being provided in good faith. We support the assignment of a dedicated Tooling Specialist and view this document and the corresponding training during your visit as a foundation for building internal knowledge. We also have a series called “Tooling Time” in our Media Gallery that thoroughly covers agitation, and a series of blog posts released directly from the lab with thorough explanations of various problems in auger filling and product performance that we highly recommend reviewing.

Scope and Limitations

The information provided reflects common auger filling principles that apply to many applications under typical conditions.

• Content is educational and concept based.
• It is not application-specific instruction.
• Testing is required to confirm suitability.

Auger filling performance depends on variables that can change over time, including product condition, bulk density, particle size, flow behavior, aeration, container geometry, equipment configuration, and operating technique.

Because of this:

• Results cannot be predicted from written guidance alone.
• Tooling selection and setup must be validated through testing.
• Deviations from these guidelines are normal and expected.

Any tooling changes, setup adjustments, or operating decisions made outside of supervised training or formal testing are the responsibility of the customer.
 

Acknowledgment

By using this guideline, the customer acknowledges that auger filling applications vary and that final responsibility for production settings, tooling use, and validation rests with the customer.

Customer Questions

1. What Are Common Tooling Mistakes?
 

Alignment Verification

• Have you verified machine alignment using the provided alignment hub/shaft?
• Are you hearing any rubbing or grinding noises that could indicate misalignment?
• Is the machine shaking during operation, suggesting components may be out of alignment?

Failure to verify alignment is one of the most common and damaging mistakes. If any component of the filler is out of alignment, tooling performance becomes unpredictable and often results in damaged components and poor accuracy. Misalignment is typically indicated by audible rubbing or grinding noises and may also cause visible machine vibration or shaking.
 

Tooling Gap Setup

• Have you set the correct gap between the bottom of the auger and the lip of the funnel?
• Is the gap too small (risking damage) or too large (causing excess product drip between cycles)?
• Are you using the provided gap gauge to properly set the tooling gap?

With non-free-flow tooling, an improper auger-to-funnel gap can cause serious issues. Too small of a gap can result in contact and damage to the auger or funnel lip. While too large of a gap can lead to excess product dripping between cycles. All-Fill and Auger Fab provide a gap gauge specifically to help prevent these issues and ensure proper setup.
 

Spinner Plate Gap

• Is the spinner plate gap set correctly for your specific product?
• Could the current gap be causing product leakage or poor performance?
• For larger particulates, have you increased the gap appropriately?
• For very flowable products, have you reduced the gap enough to control material flow?

In free-flow tooling applications, an improperly set spinner plate gap can cause product leakage, inconsistent performance, or even a tooling jam. In severe cases, this can result in the auger stud snapping and other mechanical failures.

As a general guideline:

• Larger particulates require a larger gap.
• Very flowable products require a smaller gap to effectively hold back material.
   

Understanding Tooling Clearance

• Is there sufficient clearance between the auger and funnel for your product’s particle size?
• Have you evaluated the granule size of your material to determine proper clearance?
• Are you using the correct size mismatch to achieve proper clearance (auger vs. funnel/spinner plate/clamp ring)?
• Could insufficient clearance be causing jams, product degradation, or damaged tooling?

Clearance refers to the gap between the auger and funnel.
Insufficient clearance can lead to product degradation, jams, and damaged tooling.

Clearance is typically determined by visually evaluating particle size:

• Coarse table salt (~1/8” diameter): Requires 2–3 sizes of clearance.
• Fine table salt: Typically requires 0–1 size of clearance.
• Whole bean coffee: May require 4+ sizes of clearance.

Clearance is achieved by using a mismatched set of tooling sizes.
For example, if you have a #20 auger and funnel and require two sizes of clearance, you would either:

• Use an auger two sizes smaller than #20, or 
• Use a funnel, clamp ring, and spinner plate two sizes larger than #20.

Proper clearance is critical to achieving smooth flow and preventing jams.
 

Heat Generation

• Are you monitoring tooling temperature during operation?
• Have you noticed any continuous or uncontrolled temperature increases?
• Could heat buildup indicate misalignment, insufficient clearance, improper spinner plate gap, or excessive overflight?
• Is the heat stable and normal for the product, or is it trending upward and indicating a potential jam?

Unmonitored heat generation can be an early warning sign of a developing tooling issue.

Heat can result from:

Some products naturally generate stable heat due to abrasion, which can be normal. However, a continuous and uncontrolled rise in temperature is often an early indication of a future jam or tooling failure.

Head Pressure Control

• Is your hopper maintaining consistent product levels?
• Could fluctuating head pressure be impacting weight accuracy?
• Are your infeed systems and level controls properly programmed to maintain stable head pressure?

Unstable head pressure can cause significant weight variability and unpredictable performance. Since most auger fillers operate volumetrically, they rely on consistent head pressure to maintain accuracy. When hopper levels fluctuate, head pressure changes, and so does fill weight. Poorly programmed or inconsistent infeed systems and level controls are common contributors to this issue.

Avoid Dry Running

• Is the machine being operated without product in the hopper?
• Could metal-on-metal contact be occurring due to a lack of product centering the tooling?

Running the machine empty is a fast way to damage tooling. Without product present to help center and cushion the tooling, metal-on-metal contact can occur. This can damage the auger flights and the interior walls of the funnel, significantly shortening tooling life.

2. How Should Tooling Be Properly Handled and Stored?

• Is your tooling stored in a proper racking system when not in use?
• Is tooling being stacked unsafely on carts or surfaces?
• Could accidental drops or improper storage be causing unseen damage that affects performance?

Tooling that is not stored in a dedicated racking system is at high risk for unintentional damage. Stacking tooling precariously on carts or other surfaces increases the likelihood of drops, dents, or warping, some of which may not be immediately visible but can negatively impact performance and accuracy. To protect your investment and maintain optimal performance, the use of a proper rack storage system is strongly recommended.

 

3. How Does Speed Impact Accuracy?

• Are you running at a speed that balances both production output and accuracy?
• Have you tested whether your product performs better at 450, 600, or 750 RPM (clutch brake units)?
• If using a servo motor, have you optimized RPM for this specific product?
• Is the product free-flowing (potentially benefiting from higher RPM)?
• Is the product non-free-flowing (potentially benefiting from slower RPM)?
• Are you standardizing at 600 RPM when possible to simplify changeovers and maintain recipe consistency?

As a general rule, the faster you run, the more accuracy can suffer. Conversely, slower speeds typically improve accuracy. While this applies to most applications, there are exception, some materials actually perform better at higher RPMs. Determining the optimal speed often requires testing and trial and error. Our standard clutch brake machines use a three-step pulley system: 450 RPM, 600 RPM, and 750 RPM. Servo-driven machines offer significantly more flexibility with nearly unlimited speed adjustability. We typically run most products at 600 RPM as a baseline and adjust only when product performance requires it. Very non-free-flowing materials generally perform better at slower speeds, while very free-flowing materials often run better at higher speeds. However, exceptions exist. Whenever possible, we standardize at 600 RPM to maintain uniformity across recipes and reduce the need for belt adjustments on clutch brake units. This approach helps minimize changeover time and simplifies overall operation.
 

4. What Type of Agitation Is Right for My Application?

We have a thorough set of videos discussing almost all our standard agitation offerings and why which we highly recommend watching, titled “Tooling Time” in our Media Gallery.

General Guidelines:

Standard Slow-Speed Agitator
This is the best starting point for most products and where the majority of testing should begin. If performance issues arise, adjustments can then be made based on the specific product characteristics and observed behavior.

Flake Blade Agitators
Flake blades are ideal for leafy, irregular, light-density, and typically free-flowing blends such as parsley, basil, or thyme. Due to their low density, these products often “turn” or rotate as a mass inside the hopper instead of feeding properly into the tooling. Flake blades help break up that mass flow and improve product movement into the funnel.

High-Speed A3 or D-Blades
Unlike slow-speed agitators, these blades mount directly to the auger shaft and rotate at auger RPM. They are best suited for very non-free-flowing (NFF) products that require additional encouragement to feed into the tooling or that tend to stagnate in the funnel taper around the auger. These styles provide more aggressive product movement.

Additional Agitation Options
We also offer other agitation styles that are evaluated on a case-by-case basis. In these situations, we recommend sending product samples to our test lab to determine the most appropriate solution.

5. How Should the Machinery Be Emptied Safely?

• Are you using test mode and the “empty hopper” function when running standard or larger tooling?
• Have you reduced the auger RPM before emptying the hopper?
• When using smaller tooling, are you removing the tooling and manually emptying it to prevent overheating?
• Do you have a safe and effective method (bucket, bag, etc.) to collect product during manual emptying?

Standard and Larger Tooling

• Stop the machine
• Enter Test Mode
• Reduce the auger RPM 
• Select "Empty Hopper"

This allows the auger to run at a reduced speed until the hopper is empty. The auger can then be turned off once the product has been fully evacuated.

Smaller Tooling

With smaller tooling, extended run times during hopper emptying can generate excessive heat and potentially damage the tooling. For this reason, it is recommended to remove the tooling from the machine and manually empty the remaining product. While this process can be messy, placing a bucket or bag beneath the machine typically allows the tooling to be removed safely and most of the remaining material to be collected efficiently. Some creativity may be required depending on the specific machine configuration.

 

Some High Level Notes Regarding Auger Filling:

Understanding Product Variability in Auger Filling

The auger filler and tooling will do the same thing repeatedly, but the product typically won’t. There’s no magic behind it, just product behavior. Any variation is typically related to product blend, density swings, agitation, or machine and tooling setup or some sort of variable that’s happening within the product.

Getting Started
Start each test by getting a density and observing product characteristics (i.e. flow, granule size, aeration level).

This can all impact rate and accuracy:

• Bulk density can be impacted by humidity, aeration, degradation, head pressure, and agitation.

• Aeration typically lowers density which can cause a decrease in cpm.

• Densification or degradation can cause an increase in density and increased rate.

• Head pressure fluctuations can cause unpredictability.

Tooling Sizes
The larger the tooling, the faster it is. The smaller, the slower. The larger the tooling, the less control you have so accuracy can be worse. The smaller the tooling the more control you have and typically accuracy is better. There are many caveats to this, but this is the general rule.

Container Dimensions
Container dimensions physically limit tooling size, so before doing a ton of math to size the tooling ideally, look at the physical limitations. If larger tooling would be ideal in terms of rate, but you can’t fit that size tooling in the container, it’s irrelevant.

Drip Control
Some products will drip between cycles from the bottom of the tooling. Typically, this is eliminated with drip washers, grid restrictors, or cutoffs. This takes trial and error. The larger the tooling, the worse the drip typically. On VFFS machinery we typically see the best success with positive cutoff devices, however they’re the most expensive solution.

Agitation
Continuous agitation can help keep a product in a homogenous state; however it can also damage and alter product consistency. Fill agitation with a delay is typically the best option and one we use for about 90% of products. This means the agitator runs at the same time as the auger and shuts off when the auger is off. The off delay allows the agitator to run for a set duration after the auger has stopped. Agitation can be used to increase the flow of products, or it can cause issues in some by causing variability in weights. Sugar or salt for instance in a pure free flowing state, don’t require agitation and perform worse with agitation engaged in some applications. For these applications no agitation was used to achieve ideal performance.

Product Characteristics
Products all land on a spectrum of product characteristics: Free Flowing to Non-Free Flowing and anything in between is usually categorized as a “Tweener” meaning it has both characteristics to some extent. These products are the hardest to control and identify the proper tooling for. At rest they may be densified and non-free flowing, but when agitated fluidize and turn free flowing. They’ll tend to change back and forth during production, causing fluctuations in performance. The best option is to try and get the material to favor a state of either primarily non free flow or free flow by utilizing or not utilizing agitation. Continuous agitation can persuade a product to stay free flow, whereas with fill and no off delay can help it stay more non free flow. Again, a massive amount of nuance to this.

When testing and dialing in a product, change one variable at a time and see what the impact is. Do not change multiple variables at once or it will be hard to identify what has improved or worsened performance.