PACKAGE FEEDBACK CONTROL SYSTEM AND ASSOCIATED METHODS

A method and apparatus for producing product packages comprises operating first and second feedback control loops where product package weight is averaged and used to determine one of two possible adjustments to change the product fill rate and the volume of the product. The feedback loops operate in one of a plurality of index levels. The first feedback loop seeks to improve performance by making adjustments to the fill rate and volume of the product, while incrementally moving to more stable index levels requiring tighter tolerances and package weight averages based on more product packages. The second feedback loop seeks to preserve stability by making its own adjustments to the fill rate and volume of the product if large product package weight fluctuations are sensed. The second feedback loop can move operation to less stable index levels having wider tolerances and package weight averages based on fewer product packages. 1. A method of producing on an apparatus a plurality of product packages by adjusting on an ongoing basis a fill rate at which the product is filled and a corresponding product volume contained within the pouch , the method comprising:while operating the apparatus in one of a plurality of index levels, forming, filling, and sealing the product packages using initial values for the fill rate and the volume;measuring a weight of the product packages as they are produced by the apparatus; calculating, based in part on the measured weights, a first adjusted measure of the fill rate and a first adjusted measure of the volume;', 'comparing the first adjusted measure of volume against a plurality of first threshold levels, each first threshold level corresponding to one of the plurality of index levels, the first threshold levels comprising a widest first threshold range at a first index level and a narrowest first threshold range at a second index level; and, 'in a first feedback control loop calculating, based in part on the measured weights, a ...