Food Production Weight and Fill Check Checklist [FREE PDF]

Accurate weight and fill control is mandated under FDA regulations 21 CFR 151 and the Fair Packaging and Labeling Act (FPLA) to ensure consumers receive the declared net quantity of food products. GMP 21 CFR 110.80 and HACCP Codex Alimentarius principles require in-process monitoring of fill weights as a critical preventive control against underfill and overfill deviations. SQF Code Edition 9 Section 7.2 and BRC Global Standard Issue 9 Clause 6.2 further require statistical weight monitoring, do

Industry: Food Processing
Frequency: Per Event
Estimated Time: 20-35 minutes
Role: Production Supervisor
Total Items: 36
Compliance: FDA GMP 21 CFR 110.80 - Processes and Controls, FDA FSMA 21 CFR 117.135 - Preventive Controls, HACCP Codex Alimentarius CAC/RCP 1-1969 Rev. 4, SQF Code Edition 9 Section 7.2, BRC Global Standard Issue 9 Clause 6.2

Pre-Run Scale & Equipment Verification

Confirm all scales and fill equipment are calibrated, zeroed, and functioning correctly before beginning production weight checks.

Has the checkweigher and/or bench scale been calibrated within the required frequency (daily or per run)?
Has the scale been zeroed (tared) with the appropriate container/packaging tare weight prior to checks?
Has a certified test weight (NIST-traceable) been used to verify scale accuracy at the start of the run?
Is the filler or volumetric fill equipment set to the correct target weight or volume for the active product SKU?
Are the upper and lower control limits (UCL/LCL) programmed into the checkweigher for the current product?

Declared Net Weight & Fill Target Parameters

Record and confirm the declared net weight, target fill, and acceptable tolerance range for the product being run.

What is the declared net weight printed on the product label (in grams or ounces)?
What is the target fill weight set for this production run (including any defined overage)?
Is the acceptable fill tolerance range (e.g., ±2%) documented in the product specification sheet and available at the line?
Has the product specification and weight control plan been reviewed and signed off by QA for this run?
What is the minimum acceptable fill weight (MAV - Minimum Acceptable Value) for this product in grams?

In-Process Weight Sampling

Conduct systematic weight checks at defined intervals during production. Document individual sample weights and compare against target and MAV.

Were the first 5 units of production weighed and confirmed within the acceptable fill range before full-run release?
Are weight checks being performed at the defined frequency (e.g., every 15–30 minutes or per the quality plan)?
What is the average net weight of the last 5 samples weighed (in grams)?
Did all individual sample weights in the last check round meet or exceed the MAV?
Has the weight check data been recorded in the production quality log with time, line, and sample count?
Have weight check results been entered into the statistical process control (SPC) system or run chart?

Inline Checkweigher Performance

Verify that the inline checkweigher is correctly rejecting underweight and overweight units and that the reject system is functioning.

Was a challenge test performed on the checkweigher using a known underweight unit at the start of the run?
Did the checkweigher correctly reject the underweight test unit and activate the reject confirmation indicator?
Is the checkweigher reject bin being monitored and cleared at regular intervals to prevent backup and missed rejects?
What percentage of units was rejected by the checkweigher during the last production hour?
Has the checkweigher event log been reviewed for any alarm or fault conditions during this run?

Fill Uniformity & Visual Inspection

Assess visual fill levels, headspace, and package integrity to confirm consistent fill and prevent consumer complaints.

Does the visual fill level appear consistent and within the defined headspace specification across sampled units?
Are there any units with visible underfill, overfill, or product splatter on container exterior?
Have a representative sample of containers been examined for seal integrity and package completeness?
Has a photo of representative filled containers been captured for this inspection event?
Are fill nozzles, volumetric pistons, or auger fillers visually free of blockages, wear, or buildup that could affect fill accuracy?

Deviation Identification & Corrective Action

Document and resolve any weight or fill deviations identified during this inspection event, including product disposition decisions.

Were any weight or fill deviations identified during this inspection event?
Has all out-of-specification product been placed on hold with a hold tag and segregated from conforming product?
Has the root cause of the fill deviation been identified and documented (e.g., filler calibration drift, product viscosity change, hopper level)?
Has the corrective action taken (e.g., filler adjustment, recalibration, re-sort of held product) been documented with outcome?
Has the QA Manager or Production Supervisor been notified of any deviations exceeding the critical limit threshold?

End-of-Run Weight Reconciliation & Records

Complete end-of-run weight data review, reconcile production records, and ensure all documentation is filed for regulatory retention.

Has the full production run average weight been calculated and confirmed to meet the declared net weight requirement?
Have all weight check records for this run been signed, dated, and submitted to the QA records system?
Has the checkweigher's data log for this run been exported and saved to the facility quality management system?
Is the total number of rejected units from this run within the acceptable reject rate defined in the quality plan?
Additional observations, comments, or recommended process improvements for this weight and fill inspection?

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Why Use This Food Production Weight and Fill Check Checklist [FREE PDF]?

This food production weight and fill check checklist [free pdf] helps food processing teams maintain compliance and operational excellence. Designed for production supervisor professionals, this checklist covers 36 critical inspection points across 7 sections. Recommended frequency: per event.

Ensures compliance with FDA GMP 21 CFR 110.80 - Processes and Controls, FDA FSMA 21 CFR 117.135 - Preventive Controls, HACCP Codex Alimentarius CAC/RCP 1-1969 Rev. 4, SQF Code Edition 9 Section 7.2, BRC Global Standard Issue 9 Clause 6.2. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Food Production Weight and Fill Check Checklist [FREE PDF] cover?

This checklist covers 36 inspection items across 7 sections: Pre-Run Scale & Equipment Verification, Declared Net Weight & Fill Target Parameters, In-Process Weight Sampling, Inline Checkweigher Performance, Fill Uniformity & Visual Inspection, Deviation Identification & Corrective Action, End-of-Run Weight Reconciliation & Records. It is designed for food processing operations and compliance.

How often should this checklist be completed?

This checklist should be completed per event. Each completion takes approximately 20-35 minutes.

Who should use this Food Production Weight and Fill Check Checklist [FREE PDF]?

This checklist is designed for Production Supervisor professionals in the food processing industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.