Product Spacing Problems

Problem

Spacing between products is uneven — gaps open and close through the run, products touch or overlap, or spacing looks correct at low speed but bunches at production speed.

Possible Causes

1. Infeed speed ratio to machine speed is incorrect for the format.
2. Chain flights or lugs are worn, changing the effective pitch.
3. Products slip on the infeed surface — contamination or reduced grip.
4. Hand-feeding rhythm does not match machine pitch (where applicable).
5. Guide friction holds products back unevenly.

What to Check

• STEP 1Measure the spacing over cycles.Watch several consecutive products: even release and even arrival are the baseline.
• STEP 2Verify the speed ratio.Compare the infeed/machine speed ratio with the recipe values for this format.
• STEP 3Inspect flights and lugs.Look for wear and residue that alter the spacing the elements define.
• STEP 4Check the infeed surface.Confirm the surface is clean and provides the grip the product requires.
• STEP 5Re-check at production speed.Spacing acceptable only at low speed will not survive production.

Corrective Actions

• Correct the speed ratio and store it in the verified recipe.
• Replace worn flights and lugs via the spare parts request form.
• Clean infeed surfaces and guides on the daily routine.
• Where hand-feeding is used, match the rhythm to the machine's pitch and train operators accordingly.