Decide what the particle is for
Some chili sauces are defined by visible pieces; others need a smooth dispersion with no seed fragments. Write the target as a product property: largest intended piece, acceptable fines, seed/skin presence and the measurement temperature. “Chunky” or “smooth” alone is not an acceptance criterion.
Find the first point of change
Cutting sets the initial distribution. Blending can round edges or break fragile pieces. Pumps, valves and filler nozzles can crush or bridge inclusions. Sample at the cutter outlet, after blending, at the pump discharge and at the filler supply. If the piece is already missing at the first sample, downstream changes cannot recover it.
Choose a seed and skin policy
Retain: keep seeds and skin when they are intended; confirm the largest particle passes every downstream opening. Separate: use refining or screening to remove a defined fraction; record both outlet masses and the edible solids lost with rejects. Partial: remove coarse seed and skin while retaining some texture; define the screen and the acceptance sample before comparing suppliers. The policy belongs in the enquiry, not only in the recipe.
Make the acceptance sample repeatable
State where the sample is taken, when in the batch, at what temperature and by what method. Wet screening, image analysis and visual grading answer different questions. Keep the same method between trials and between the factory and site test. A screen aperture is not a guaranteed finished particle size.
Check cleaning and changeover
Seeds, skins and fibrous pieces lodge in valve cavities, pump rotors, screen frames and filler manifolds. Include those locations in the cleaning inspection and verify them after the most persistent product. A smooth run does not prove the chunky product can be cleaned.
| Checkpoint | What can change | Evidence to record |
|---|---|---|
| Cutter outlet | Knife and screen condition, feed moisture and throughput can shift the initial size distribution. | Size distribution, fines share and product temperature at a stated throughput. |
| Blender | Agitator shear, mixing time and the order of additions can round or break fragile pieces. | Samples at the start, middle and end of the batch; piece count, size and shape. |
| Pump and valves | Rotor or impeller action, speed, restrictions and dead corners can crush or smear inclusions. | Profile before and after transfer, plus flow and pressure at the same setting. |
| Filler | Nozzle and valve passages, dose speed and hopper level can bridge or split pieces. | First, middle and last packs; piece distribution and dose mass. |
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