Method of rejecting a defective unit dose pouch from a manufacturing line

An in-line method of rejecting composition-filled pouches having a defect from a pouch converting line, wherein the pouch converting line comprises a platen having a surface, the platen comprising a plurality of pouch cavities in the surface of the platen, wherein each of the pouch cavities is:

• b) surrounded by a plurality of platen edges;
• c) arranged in lanes and rows such that the location of each cavity is defined by a single lane, L disposed between Lane L−1 and Lane L+1, and a single row, R disposed between row R−1 and Row R+1;
• and
• d) in combination with the plurality of platen edges defines an area comprising at least four zones selected from the group of:
• Top Zone adjacent to Row R−1;
• Bottom Zone adjacent to R+1, a Left Zone adjacent to L−1;
• and a Right Zone adjacent to L+1;
• the method comprising the step of inspecting a first composition-filled pouch located in the cavity at lane, L, row, R for a defect in at least one of the four zones, such that if a defect is detected in:
• i. the Top Zone, the first composition-filled pouch is rejected and a second composition-filled pouch if present in a cavity at Lane, L, row, R−1 is rejected;
• ii. the Bottom Zone, the first composition-filled pouch is rejected and a second composition-filled pouch if present in a cavity at Lane, L, row R+1 is rejected;
• iii. the Left Zone, the first composition-filled pouch is rejected and a second composition-filled pouch if present in a cavity at Lane, L−1, row, R is rejected;
• iv. the Right Zone, the first composition-filled pouch is rejected and a second composition-filled pouch if present in a cavity at Lane, L+1, row, R is rejected.