The type of liquid filler machine a business needs will depend on the types of products and containers used. There are many different machines available for various tasks and container sizes, and each one works on a unique set of principles.
Choosing the right filling machine manufacturer will help speed up production and improve product quality. It will also minimize downtime and increase productivity.
Types of Liquids
Choosing the right liquid filling machine for your products depends on several factors, including product viscosity, container types, and production rates. For example, a machine that handles thick liquids such as oil requires different equipment than one that fills water-like products like juices and sodas.
The size and shape of the containers also determine which type of machine to use. For instance, a small bottle filled with glycerin soap or deodorant will require a much simpler machine than a large container of pickles.
Liquids with particulates, such as fruit pieces or fibers, also have special requirements. This is because these elements can shear the liquid during production, resulting in unwanted viscosity changes. Therefore, these types of products require a specific type of machine that uses specialized pumps and valves. In such a machine, the product’s viscosity is controlled by the pressure difference between the reservoir and the bottle. This ensures that the liquid is pushed into the bottle without shearing it.
Containers
Different products require a specific type of container. For example, a glass carboy is typically used for brewing or industrial chemicals. It may be able to hold liquids up to 5 gallons and is often paired with a conveyor to move containers through the filling machine.
Some systems wash the containers before feeding them into the machine to prevent contaminating the liquids and to reduce waste. Other systems pre-sterilize them with hydrogen peroxide or another agent to prevent microbial contamination.
A linear filler uses a conveyor belt to move containers in a straight line while a rotary filler moves them in a circular motion. Both machines use gravity or pressure filling depending on the product and volume requirements. They can also incorporate capping or labeling as part of the system. They can also be air-powered to operate nozzles, diving mechanisms and bottle stops. This makes them more efficient and able to handle a larger range of bottle sizes than pumps.
Packaging Materials
Modern linear filling machines work with various materials, including powdered substances such as sugar, salt and milk powder. These are poured into containers using a hopper that is fitted with sensors to monitor the amount of product. This ensures that each container is filled consistently and accurately.
A servo system also enhances the performance of these machines, making them more stable and accurate. This helps to reduce contamination problems and prevents errors caused by mechanical problems. It also improves energy efficiency by reducing the number of filling nozzles.
Other factors to consider when choosing a liquid filling machine include its viscosity and the type of container. Less viscous products like water flow easily while thicker or high-viscosity liquids need more specific equipment. The level of automation and whether the machine can handle different types of containers are also important considerations. For example, some machines can be modified to accommodate plastic or glass bottles, short or tall, or have different opening sizes.
Filling Principles
Regardless of the type of liquid being packaged, there are several machines that can help to ensure the process is executed correctly. These machines include a hopper where the product is stored, a filling machine that uses nozzles to dispense the liquid into the containers, and supplemental machines like a capping machine and a labeling machine.
The viscosity of the liquid will also determine what kind of machine is best suited for it. Free-flowing liquids typically require overflow and gravity filling machines, while highly viscous liquids should be filled using piston or peristaltic pump fillers.
For items sold by weight or high-value products that demand accuracy, net weigh filling machines prevent over or under-filling by weighing each container as it is being filled. In addition to reducing production time, these machines also cut down on product waste and improve system performance and quality control. This makes them ideal for a wide variety of applications.