Autonomous overfill control
ExactFill continuously retunes mixed-brand food packaging lines, pulling typical overfill from around 3% down toward a 0.05% control band—without increasing underweight risk.
Applied inside approved limits. Result verified on the next package window.
The economics of a few grams
A high-volume packaging line can process a hundred million dollars of product a year. Lines commonly run around 3% above target to stay safe. Closing that gap to a 0.05% control band recovers millions of dollars of raw material per line, per year.
RAW MATERIAL GIVEN AWAY ON A TYPICAL HIGH-VOLUME LINE SINCE YOU OPENED THIS PAGE
$0.10 EVERY SECOND · $8,219 EVERY DAY · $3M EVERY YEAR
$0.00
Underfilling creates immediate risk: rejects, complaints, compliance problems and downtime. Overfilling creates a quieter cost, spread across millions of packages. Operators protect the line by adding margin.
The weigher, checkweigher, PLC and sensors often come from different manufacturers. Each machine knows its own state. No neutral system learns how the full line behaves and tunes it as one process.
Illustrative line economics. Actual savings depend on throughput, product cost, process variation, legal metrology requirements and current operating performance.
Four levels of control
Most plants already manage overfill. The difference is who makes the decision, how often it happens, and whether the system can learn from the result.
Operators set a generous target to stay safely above the minimum. Typical giveaway: 2–4%.
Engineers review reports and update settings after the process has already drifted.
Legacy controls apply predefined corrections when a threshold is crossed.
The system learns the current line behavior, acts inside approved limits, verifies the result and retunes again—holding a 0.05% band instead of a 3% cushion.
LEVELS OF LINE AUTONOMY
Every solution on the market today stops short of touching the machines. That gap is the giveaway.
L1
An operator weighs sample bags every hour on a bench scale and turns the knobs by hand. The default state of most lines on earth.
WHO ACTS: A HUMAN, HOURLY
L2
SPC dashboards, statistical quality-control suites, cloud analytics with AI "insights and suggestions." The data is real. A human still has to read it, walk to the machine, and act.
WHO ACTS: A HUMAN, EVENTUALLY
L3
OEM checkweigher-to-filler trend loops. Rule-based, two machines at a time, and effectively locked inside one vendor's ecosystem. Better than nothing. Blind to the rest of the line.
WHO ACTS: ONE BRAND, PARTIALLY
L4
Every machine on the line, any vendor, tuned by a neural net in real time — continuously, without a human in the loop. Overfill goes from 1–3% to fractions of a percent, and compliance documents itself.
WHO ACTS: THE SYSTEM. ALWAYS.
One bounded control loop
ExactFill runs locally at the edge. It connects the line, observes the full weight distribution, calculates a bounded correction, applies it and verifies the result on the next production window.
Connect the weigher, checkweigher, PLC and available sensors across supported vendors.
Model how product, speed, machine state and prior corrections affect final package weights.
Write small parameter changes inside customer-approved limits and existing compliance constraints.
Confirm the effect on subsequent packages, update the model and continue tuning.
INFERENCE / EF-01 EDGE MODEL
A compact network runs locally on every package window. It maps the full sensor state of a mixed-vendor line onto the specific setpoints each machine needs — no cloud round trip, no operator in the path.
Checkweigher distribution, filler state, line speed, product batch, ambient conditions.
Learned response model of this specific line, updated continuously against verified outcomes.
Bounded setpoints written to the machines: dose time, cutoff offset, feed rate — inside approved limits.
Designed for repeatable deployment
ExactFill is standardized around a preconfigured industrial edge computer and reusable machine connectors—not an open-ended six-month integration project.
Power, network and supported PLC or machine interfaces.
Select machine profiles and validate signals in the guided setup.
Begin in listen-only mode, then enable bounded automatic tuning.
Hardware + software
ExactFill is not a dashboard subscription. It is the EF-01 edge controller: a fanless industrial unit that clips onto the DIN rail in the cabinet you already have, talks to every machine on the line regardless of badge, and runs the control model locally.
EF-01 / INSTALL SEQUENCE
The EF-01 clips onto the DIN rail in the cabinet you already have.
What it's worth on your line
The license is a fraction of the raw material recovered. Move the sliders to your own throughput and current overfill to see what one line is losing today.
Illustrative model, not a guarantee. Achievable residual overfill is constrained by filler capability, product variability and legal metrology rules in the destination market. Actual results and pricing vary by line, product, baseline and deployment scope.
Start on a single line and let it prove the number against your own baseline. Once the integration is standardized, the remaining lines in the plant use the same machine profiles — and a 100-line site multiplies the recovery accordingly.
Scaling assumes comparable throughput and baseline overfill per line; actual results vary by product and equipment.
The distinction
Collect and visualize data
Generate reports and alerts
Recommend operator actions
Reads the mixed-vendor process
Chooses a bounded correction
Acts, verifies and retunes continuously
ExactFill is the autonomous line-control product built by Automatence
Start with one line
For 30 days ExactFill only listens. It establishes your baseline, quantifies the giveaway you're paying for today and shows whether the line is a strong candidate for automatic tuning — without writing a single parameter.
Start your 30-day listen-only trialNo machine writes / No production risk / Cancel anytime