A Diagnostic Study on Managing Packaging Weight Variability in Chilli Powder Manufacturing Using Statistical Process Control

Abstract

In the food processing industries, weight variation in the net product content is frequently noticed, particularly in the case of spices (Chilli Powder). Since it directly affects customer satisfaction and brand image, the variation of excessive weight in the spice packing, either more or less than the legal minimum weight, is a serious problem. This weight fluctuation is a possible waste that could result in different product quality, higher production costs, and worse profitability. Product weight variations during packaging are still a major issue due to human error, machine calibration, raw material variability, environmental variables, and standard operating procedures. Chilli powder is fine and sticky, thus the auger filler nozzle can affect weight variations in packaging. A poorly sized or residue-clogged nozzle might inhibit chili powder flow, resulting in irregular fills. Proper nozzle design and regular cleaning reduce these difficulties and will help the chilli industry standardize products, cut waste, and compete globally. Quality is essential in any productive industry, including manufacturing and services. Several techniques have been consolidated to analyze the standardization of production process quality. The research method included data collection, statistical analysis and process control to evaluate packing machine component changes. A large sample size was employed to measure spice packet weight before and after change to ensure statistical significance. Descriptive statistics, a two-sample t-test, and variance tests (F-test and Levene's test) assessed mean weight and variability. SPC used X-bar and R charts to monitor how stable the process was, set control limits, and calculate process capability (Cp and Cpk) based on the set specifications. These tools helped check how effective the component change was. Before changing the component, there were 38 outliers on the X-bar chart and 5 on the R chart. After making the change, outliers on both charts were very few and insignificant. This study recommends modifying the auger filler nozzle to help lower packing weight variation.