Skip to content

The Right Filling Machine for Products with Particulates

Jellies, jams, salad dressing, and hand soaps are some of the products with particulates. Particulates added to those products may be in grainy bits for hand soaps, large fruit chunks for jams and jellies, or may be in fine particulates. There are various types of filling machines for filling products with particulates. However, it is important to note that there is only a specific liquid filler that will match to an individual product and the granular-form it contained. Meaning to say, the selection of filler is dependent on the characteristic of the products and its particulates. There are basically three filling machines best in filling products containing particulates and they are listed below:

filling machine

· Overflow filler can fill thin liquids and can handle products with smaller particulates. This filling machine uses special nozzle that seals the container’s opening and fill products to the bottle. Once the product reaches its pre-defined level, the supply will stop, allowing all containers having the same equal fill. Even though there are slight variations with the inside volume of the bottle, overflow filler is still consistent in achieving level fill. Overflow filler is not applicable in filling products in bigger particulates as this can block the nozzle’s opening and will cause inconsistent fill that will eventually damage the nozzles.

· Pump Filler can handle products higher in viscosity and products with large particulates. The type of pump used in pump fillers will depend on the particulates and products that will be filled in the container. Since this filling machine can handle larger particulates, it is then understood that it can also fill thick products with smaller particulates. Pump fillers are not applicable for products that are extremely high in viscosity with larger particulates. Forcing the filler to these extremities will create inconsistency on the filling process as larger particulates may block the products pathway, which in the end will cause damage to the machine.

· Piston Filler is the best liquid filler to use for filling products that are highly viscous with larger particulates. This filler can handle products which are extremely thick like tomato paste and putties. Piston filling machine can provide a highly accurate volumetric fill. This type of filler uses a piston to pull the product into a cylinder. The cylinder will then allow ample area to handle larger particulates, which the pump filler cannot accommodate. With the use of the piston and with the right nozzle, larger chunks like fruits in jams can be pulled into the piston filler cylinder and pushed out into its waiting container.

Before purchasing a filling machine for products with particulates, it’s important to take into account first the types of products and the particulates it contained. Overlooking this aspect might create mistakes that will eventually bring inaccuracy to the entire filling procedure.

Why Piston Filling Machines is an Ideal Choice

What type of filler should I use to my product is probably the basic question packagers asked to themselves. There are literally too many assortments of filling machines that can be used in any facility. Every type of filler offers different advantages and benefits. However, there is only one filling machine that can satisfy and cater all of your filling needs. Most of the time, overflow and gravity fillers are used for filling thin products, while piston filler and pump filler will be used in filling thicker products. For special cases, the general rule will be altered if a corporation is dealing with products with different viscosity. Industries that fill products ranging from thin to thick and free-flowing products will require one specific machine that is versatile in handling the filling complexity.

Piston Filling Machine

As mentioned above, piston filler is best in filling products that are high in viscosity. But, only a few knew that piston filling machine is literally versatile in handling both thin and thick products. As a matter of fact, it is an ideal filler for any filling project.  Akin to overflow filler, piston filler also offers accurate volumetric filling, but in other ways as this liquid filler has its own share of limitations. Most packagers commonly used piston filler for various reasons that will be discussed below:

1. Piston filler doesn’t only handle multiple products with different viscosity, but, it can also fill products with different container sizes and shapes. However, as the range of volume become extreme, one piston might not be able to do the task alone. Hence, it requires two or more piston to complete the filing cycle. It is also important to note that with this instance, changeover may take some time.

2. Piston filling machine can be manufactured in fully automatic form, which means that it can work with other existing equipment in the facility, like power conveyor system, capping machines, and labeling machines to create an entire packaging line. To add up, it can also be built as tabletop or portable semi-automatic machines best fit to companies that handle low to medium production demands.

3. Piston filler is absolutely user-friendly equipped with a PLC controlled by an easy to use operator interface that uses a touchscreen to control the time duration and delay for indexing and filling bottles. The interface also includes a simple touchscreen power on or power off button for the fill cycle and other components or machinery that created the whole packaging line.

Even though piston filler is not so accurate when it comes to economical filling, it would still be the best choice among packagers who handle numerous products that vary in viscosity. With its capacity to handle different complexity, packagers can evade the costs of buying additional liquid filler to handle another set of filling project. Thus, piston filler is a preference that should not be left unnoticed.

The Two Types of Sensors Used in Automatic Filling Machines

Increasing productivity is the primary advantage a packager could benefit from using an automatic filling machine. In most cases, filling machines work with other existing equipment in the facility, like, capping machines, bottle rinsers, and labelers. Sensors are used in automatic fillers to effectively accomplish the filling cycle. The sensors help the machine maintain its productivity by running properly and working efficiently with the entire packaging line. There are actually two main types of sensors used in automatic filling machine and they are listed below:

filling machine

1.   Count Sensor

The count sensors serve two main purposes, first is to count the number of bottles in the fill area transported by the power conveyor system. The number of bottles that will enter to the filling machine will also be equivalent to the number of fill heads attached to it. In other words, if the machine is composed of sixteen fill heads; sixteen bottles will also enter into the filling area. Once all the bottles reach its designated fill heads, the indexing system will now stop adding bottles. From there, the count sensor will perform its second purpose by becoming an activating sensor. The count sensor will then send signal to the machine that the bottles are already in place and the filling cycle should now begin.

2. Float-type sensor

The float sensor is a detecting device that ensures product availability. They are responsible in sending signal to the pump whenever the liquid level in the tank becomes low. The pump will then re-supply the tank with product so that filling cycle will continue without interruptions. Reducing operator intervention is one of the biggest benefits of float-type sensors. Float-type sensor operator doesn’t need to check and regularly add products to the supply tank. All he needs to do is to check the bulk product supply at times to ensure that the product is not running low.

Again, the two types of sensors are used in automatic filling machine. There may be other types, however, they are mostly found on specialized projects in a packaging line.

In conclusion, sensors are attached and used in filling equipment as communication device that will detect any errors arising in the entire packaging line. The detecting device allows the machine to function at its optimum efficiency and highest consistency.

 

The Five Basic Components of an Automatic Packaging Line

There are a lot of varieties of packaging equipment and each assortment differs from their specific function making the whole packaging line more productive and efficient. A packaging system can reduce the space used for equipment like filling, capping, and labeling. It doesn’t only reduce the space used in a facility, but it can also minimize the product handling time. It may only take seconds, but in business, every tick of the clock counts. Business owner will be surprised to discover how much time can be saved by merely reducing the distance traveled for each packaging phase. There are actually five basic components completing an automatic packaging line and they are listed below:

filling machines

1.   Bottle Turntable

The bottle turntable allows the laborer to quickly and easily introduce the bottles to the line. The turntable moves the bottle to the conveyor that will be transferred to the filling machine for filling. Bottle turntable comes with different sized tops to handle container sizes. There are also other turntables that make changeover from one container to the other quicker and easier.

2.   Conveyors

From the turntable, the bottles will move down to the power conveyor to be transported to the filling machine for filling, then down to the capping machine for sealing, unto the final step of labeling. Conveyors come from different sizes and can be manufactured using different belting materials like stainless steel.

3.   Liquid Filling Machine

Thin and thick liquids will not make use of the same type of filling machine as they require different filling principle. Piston filler, pump filler, overflow filler, and gravity filler are some of the filling machine’s assortments available in the market. These machines can add up to sixteen fill heads depending on the needs of the production and the desire of the end-user. Filling machine contains a user-friendly touchscreen operator interface, for all the time duration of fill times and index times. When the time duration are all set-up, it will then be saved in the memory device, available for future use.

4.   Capping machines

Once the container has been filled, it will then be transported to the capping machine ready for sealing. There are different types of capping machines. Some of which are chuck capper, spindle capper, snap capper, all of which will be dependent on the type of cap being used.

 5.   Labeling machinery

After sealing the product, the container will again be transported by the power conveyor to the labeling machinery. Labeling machine can apply labels in different ways like front labeling, back labeling and wrap labeling, and more.

The five machines completing the entire automatic packaging line may work for a majority of packaging project; however there may still be adjustments and additional packaging machines to be added like accumulating turntable. After the product has been labeled, the power conveyor will move all the products to the accumulating turntable, the perfect spot for packing station.

The Truth About Start-up Companies and the Right Filling Machine for them

All businesses regardless of how huge started from scratch and all. The first five years in running a business is remarkably the hardest and the most challenging part. Within these years, business owners deal with a lot of dilemmas and issues that need immediate solutions in order for the company to flourish. During these years, companies are literally proactive in building their reputation, expanding their networks, and attending media exposure, which can all be sum-up as product marketing. Product marketing involves sufficient fund, which is unquestionably costly but very valuable in the end. Marketing the product is indeed significant for starting companies for their product to be known and recognized by the consumers. But before the marketing and all, business owners will have to determine first what appropriate equipment to be use.

filling machine

Start-up companies begin with a limited sales area that might range from one locality, while some start-up industries are lucky enough to serve a whole state. For companies that produce smaller production demands, tabletop filling equipment is the best option. Tabletop filling machine requires two or more operators to accomplish the filling task. Operators can turn on the switch of the equipment using its finger or foot to start filling products.

All companies aim for growth or expansion in the future, of course the faster the growth, the better. However if the growth continually increases, tabletop filling machine may not be suitable for the type of production. It may become obsolete and may not be able to handle to the complexity of the production. With this instance, semi-automatic filling machine will be the best fit. One of the best things about semi-automatic filling equipment is its flexibility in working with other equipment like power conveyor systems. Furthermore, the equipment can also be added with additional fill heads depending on the needs of the packager. Thus, semi-automatic equipment is designed to grow together with the company, truly useful and cost-effective equipment.

Luck may play to some starting companies who have products that will have amazing sales in the market. For these companies, automatic filling equipment is necessary. When the product shows continuous increase in sales every time, business owners should make use of this opportunity as there will be no assurance when tastes will change. In other words, business owners should always ensure the availability of the product to please consumers. Similar to semi-automatic filling equipment, automatic filling machine can also work with a power conveyor system and can be combined with other equipment like capping machines, labelers, bottle rinsers, and a lot more. Automatic liquid filling machine can start filling without an operator to manage. It uses and indexing system to move the bottles in and out of the fill heads and uses sensors to send signals that the bottle is ready for filling. In addition, the machine also uses a touchscreen operator interface to set up the bottles and changeover. This equipment is upgradeable and best fit to those companies that produce higher production demands.

Preparing a packaging line for a starting product is very challenging. However, no company can ever escape doing this task. To be successful with this undertaking, it’s best to read more resources to come up with the right filling machine.

 

Conveyor Systems and Essential Aspects to Look For

As population continually grows and demand for supplies is constantly increasing, industries will require equipment to operate productively.  The conveyor system becomes an essential equipment in an industry to transport materials or objects from one point to another within the facility premises. These conveyor systems increase productivity without relying much on manual labor, which is undeniably expensive. Choosing the right conveyor can be successfully achieved if you study and consider every aspect written below:

bottle conveyors

1. Dimension

It’s important that the equipment you are going to purchase can handle the containers that you will be transporting. In other words, the conveyor system’s length and width should depend on the size and weight of the container after filling.

 2. Belting Materials

Conveyor systems can use different materials like rubber, plastic, or metals. Before deciding on what type of material, it’s best to determine first what product you are going to transport. There is a specific industrial conveyor for an individual product. For example, products that are corrosive should use conveyors that are built with stainless steel materials, but products that contain acids should avoid the material mentioned.

 3. Flexibility

Industrial conveyors should always meet the present demands in the facility. However, it is also necessary to consider the future expansion of your company and the expected increase in production. Thus, it is advisable to look for equipment that is flexible in handling two or more product sizes. The transporting system should be at greater widths to accommodate not only containers in ounces, but also products in gallons. Equipment’s flexibility can also be determined by studying the transporting system’s load support. All conveyor systems are manufactured with its correct tension and weight capacity. Given that, packagers can easily determine how capable and flexible the equipment will be.

4. Reliability

Contacting and discussing equipment’s performance to current users are the only ways to obtain answers on how reliable the equipment will be. Choose conveyors that have been in the operation for some time. One of the reasons they stay longer is that they are considerably showing good performance than the others.

5. Energy Efficiency

While most conveyors are designed to be energy efficient, there are still other transporting systems that are specially programmed that enables automatic functioning that will turn the equipment to “sleep mode” during periods of inactivity, which is truly more cost-effective.

To sum up, it’s important to choose conveyor systems that are easy to use, versatile, operationally safe and of course cost-effective. While there may be a lot of factors to look for, these five aspects are the most basic elements to consider before purchasing conveyor systems.

Four Pointers to Consider Before Purchasing Liquid Fillers

There are a lot of liquid fillers available in the market nowadays and it will be very unsurprising to get confused when you meet them. With all of its different specifications, assortments, capacities, and specialization, expect that the selection process will brought too much dilemmas. Every filling project requires different liquid filling machines. Thus, every filler is unique and plays significant filling task different from the others. Whatever type of equipment your production required to have; there are essential concerns to consider before jumping into finally purchasing a packaging machine. To help you achieve the right machine for your production, consider the following tips as they will guide you to the entire purchasing plan.

1. Determine the appropriate filling principle for your type of production

Filling machines have different principles of filling product. Every principle is different from the others and serves its unique purpose in the production process. It’s good to start with evaluating what kind of product you are going to pack. Thin and thick liquids or what are commonly known as low viscosity and high viscosity products require different liquid fillers to accomplish the filling process. Thick liquids use piston filler or pump filling machine, while thin liquids require overflow filling machine or gravity filler. These are general rules. However, changes may be possible for special cases like project that handles two or more products with different level of viscosity.

2. Decide how fast your production rate will be

Production rate can be calculated easily. The calculation will be made easier by deciding beforehand how many containers you wish to fill in every cycle. If liquid fillers have 4 fill heads and can complete 2 cycles per minute, then the machine can fill sixteen bottles per minute, or 960 bottles per hour. Changes in the production rate are obviously applicable by adding or subtracting the number of fill heads or through increasing the speed of the pump.

3. Evaluate if the machine can work with all types of containers

Aside from the type of product, another important thing to consider is the flexibility of the machine. Almost all industries use different bottle sizes to match every buyer’s needs. Thus, liquid fillers should work with different types of bottles used in packaging the product. Different packaging equipment requires different changeover for the sizes of the bottles. Though every machine are able to handle different container, there are still some filling machine that works better when it comes to a more speedy and efficient changeover while reducing the filler’s downtime. The changeover can cause downtime to the filler that will also result to the delay in the production.

4. Assess if the machine can work with your existing equipment

If you already have the equipment of your choice, the next essential thing to do is to asses if the machine can work with your other existing equipment. If you already ensure its versatility in working with other equipment, then expect that you are on the right track! There are plenty of automatic liquid fillers that can be matched with any existing bottling conveyors. However, it’s important to note that semi-automatic machines may not be able to work with other packaging machines. Changes in packaging will always occur anytime in the future. Always take time to evaluate if the machine is capable of working with other packaging machinery in your plant industry to refrain from investing into a machine that will eventually become obsolete.

As the internet is always accessible, it’s always best to inquire to two or more liquid filler manufacturer and always get ready with your list of all the latest and conventional equipment to speed up the decision process. Accomplishing the four tips ensure greater chances of getting the right equipment for your type of production.