A filling machine is necessary if your business involves filling pouches or bottles with food, drinks, or any other products. This is a type of packing equipment that can fill thousands of containers with specified products to a predetermined level on a regular basis. Bottles, vials, bags, cans, ampoules, drums, tubes, and glass are among the containers used.

While there are various filling machine technologies on the market, you should invest in equipment of high quality and one that is most suited to your company’s demands. The correct filling machine will help your manufacturing line run more smoothly. This article will take you through the different types of product filling machines.

Powder Filling Machine 

When it comes to filling powder products, a lot of businesses confront numerous obstacles. Especially when it comes to selecting the right powder filling equipment for their needs. In order to achieve an acceptable return on investment, you must discover filling solutions that match your needs. 

The following information will assist you in choosing the best powder filling machine or powder filler to meet their budgetary needs and consumer expectations. We will go over everything you need to know about powder filling machines.

What Is A Powder Filling Machine?

These machines are commonly known as powder fillers. They are specifically used to fill free-flowing and non-free-flowing powdered and granulated goods. The spiral feeding and light control technology enables great filling accuracy and zero-drip operation. The parts of a powder Filling machine include:

• Hopper.

The powder substance to be fed into the packaging is held in this component. Some powder fillers use level sensors that monitor the amount of powder in the hopper at any given time.

• Filling Heads.

For the filling operation, the filling heads pour powder product from the hopper into the packages.

• Mechanical Drive System.

A powder filler’s mechanical drive mechanism, which determines the motion of the machine’s moving components, can be linear or rotational. Gears, conveyors, and mechanical motors are all part of this system.

• Sensors.

Sensors ensure that the containers are properly positioned and that the fills are accurate. If no container is discovered, they tell the machine to either resume or stop filling.

• PLC (Programmable Logic Controller) Control System

Operators configure the filling process settings using the powder filling equipment’s PLC control system. A touch screen interface will be available on some computers.

• Measuring cup.

To ensure more precise quantitative fills of powder products into packaging, some powder fillers will have a measuring cup also known as a weigher.

How To Make Powder Filling Machine machine Precise

Make sure you remove any debris from your powder-filling equipment as soon as possible.

Inspect your machine on a regular basis. Each motor, electrical appliance with or without overheating, odd noise, and instrument indicators should all be inspected on a regular basis. Timely registration and maintenance are also required.

The mechanical equipment used to maintain concentration varies according to the season. Seasonal features must be able to be used in the selection of lubricants, in particular.

Application Of Powder Filling Machine

• Industry of Food and Beverage. These include items like Carbonates, Fine flour, Powdered sugar, Salt, Coffee powders packaging, Milk powders, powdered sugar, and other food products in powder form.

• Chemical Industry. This machine fills products like powdered pesticides, fertilizers, detergents, veterinary drugs, and other powdered substances.

• Pharmaceutical Industry. They include items like powdered medicine, cannabis packaging, and any other items associated with the pharmaceutical industry.

• Cosmetic industry. Cosmetic detergents and baby powders are among the products produced by the cosmetics industry.

• Veterinary industry. This equipment is very beneficial in the animal medicine industry. This is because certain animal medicine is prepared in powder form. 

• Agriculture industry. This is a very important industry. This method is used to package both powdered and inorganic materials such as fertilizers. 

Solid Filling Machine machine 

What Is It And Its Parts

The basic function of the solid filling machine is to fill containers with finished solid products before sealing them. To keep its integrity, the product must be the proper amount. Its parts include:

The hopper. This is the portion that holds the product to be filled in a container. The hopper is equipped with a level sensor to detect the amount of product in modern solid filling machines.

Mechanical motors. All mobile elements such as gears and conveyors are controlled by mechanical motors in the mechanical drive system. Depending on its design, the mechanical drive system generates rotary or linear motions.

Measuring cups. They are used to accurately fill containers by measuring the contents.

A nozzle. This is a filling head together with a tube that connects to the hopper and guides items into containers.

Sensors. They ensure that the container is positioned correctly, directly below the nozzle, and that there is no product waste when the container is not at the nozzle.

PLC control system: A PLC control system is a system in the machine that allows you to control the filling process. After you’ve built up the process, there’s no need to manually handle any of the steps.

Working Principles Of A Solid Filling Machine

The working of this machine starts with the placement of containers on conveyors for transportation. In case the solid filling machine has many heads, it will be able to fill multiple containers at once. The product is then placed in the hopper, where it will be distributed to the containers. 

The quantity of the product is determined by the machine settings. The amount of the finished packaged product is determined by setting the filling machine by weight or count. If you find the right filling machine manufacturer, you can customize your solid filling machine. 

How To Make Solid Filling Machine Precise And High-efficient

• Inspection of the solid filling machine on a regular basis

• On a regular basis, wear parts should be checked and replaced.

• Keeping a supply of high-wear parts on hand 

• Keeping the solid filling machine lubricated

Common Application Of The Solid Filling Machine

• Snack foods
• Hardware
• Any non-flowing products

Liquid Filling Machine

Manufacturers whose end products are in liquid form frequently utilize liquid filling machines. If you’re one of them, the following information is for you.

What Is A Liquid Filling Machine

A liquid filling machine is basically a machine that is used to package liquid finished products in a variety of industries.

It is worth noting that liquid products that need to be packaged differ throughout the filling phase. They can be frothy in some cases, dense, or even creamy. 

Packages also come in a variety of shapes and sizes. Tanks, buckets, bottles, tins, cans, vials, pouches, and even pots can be used. In order to ensure flawless functioning and remarkable precision, the liquid filling machines should be set and calibrated. Liquid filling machines come in a variety of shapes and sizes.

Working Principle Of Liquid Filling Machine

Liquid fillers are split into numerous types based on their functioning mechanism. That includes a high-pressure filling machine, vacuum filling machine, and ordinary filling machine. Ordinary liquid fillers work by gravity, where the liquid is poured into specific bottles due to its weight. 

However, particular standards must be followed in order to keep the fluids’ viscosity and gas-bearing capacity.

Milk bottles and grape wines are two notable examples. The ambient pressure must always be greater than the pressure in the bottles for the vacuum fillers to work.

High viscosity liquids include syrup, oil, and wine. These liquids will require this sort of filler, which is highly efficient and has a simple structure. 

In order to be functional, pressure liquid filers must always have a higher pressure than atmospheric pressure. Note that high-pressure filling and equal air pressure filling are two different types of filling.

In the case where the liquid reservoir pressure equals that of the bottle during “equal air pressure filling,” the liquid will flow into the bottles by weight. The pressure difference between the liquid reservoir and the bottle is used in the high-pressure filling, on the other hand

Types Of Liquid Filling Machines

Filling machines can also be categorized based on their applications, apart from the design. Let’s have a look at some of these filling machines in more detail.

• Gravity filling machines. They are mainly utilized in the water, wine, oil, spirits, and vinegar industries.

• Vacuum filling machines. Filling bottles with foamy products is usually done with these types of machines.

• Overflow filling machine. Filling to a level within a container is how Overflow Filling Equipment works. Even if the interior volume of a container varies slightly, the filling machines’ unique nozzles ensure that each container reaches the same level. Overflow fillers are appropriate for thin to medium viscosity materials, and they perform particularly well with foaming products.

• Hot filling machines. They fill containers with sauces, juice concentrates, and jams.

• Isobaric Filling Machines. These mainly fill containers with beer, carbonated soft drinks, sparkling wine, or even cider.

• Piston Filling Machines. They are used for Honey, Jams, Oil, Pastes, Sauces, and Cosmetic Creams. The piston pulls back to allow a set volume of product from the supply system to enter the cylinder. As the piston returns to the cylinder, the product is forced out of the nozzle and into the waiting containers. 

• Volumetric Filling Machines. They are used In the production of yogurt, milk, mayonnaise, salad creams, and oil. These devices fill each container with a precise amount of liquid. As a result of any irregularities in the form or volume of the bottles, the liquids may appear to be at different levels.

• Acidic resistant. They are used to fill Bleaches and corrosive liquids.

How To Make Liquid Filling Machine Precise

• Cleaning the cup and filtration of the water-air separator on a regular basis. Clean the filter element in mineral oil and then blast it off using compressed air.

• Replacement of abrasive seal rings on the feeding piston and below the discharging cylinder on a regular basis.

• Always avoid mixing of filling materials, as this might lead to filling volume inaccuracies and machine damage.

• To maintain the stainless steel surface of the liquid filling machine bright and clean, never scratch it with a sharp or hard edge instrument. If the surface is filthy, wipe it down with alcohol.
• Avoid unscrewing the air cylinder or adding any lubricating oil, since this is already done when it is delivered.

Common Application Of The Liquid Filling Machine

• Pharmaceutical Industry
• Chemical Industry
• Beverages

Jar/ Tin Can Filling Machine

A can / jar filling machine is basically an automatic filling and capping equipment that incorporates modern domestic and international technology. Stable operation, good sealing quality, attractive appearance, ease of use and maintenance, touch screen operation, and frequency conversion speed modification are all features of the can or jar filling production line.

Carbonated drinks, juice drinks, beer, energy drinks, and soda water can all be filled using the can/jar filling machine. Levapack is a filling machinery manufacturer that offers a complete production line for small and medium-sized businesses.

Working Principles Of Can Filling Machine

The can filling machine works on the principle of normal pressure filling. The empty can will access the lift can supporting disc after passing through the dialing wheel, and the filling valve will line with the empty can as it rises for sealing. In the meantime, the filling valve’s valve port is automatically opened. 

When the hook chain transports the filling cans to the sealing machine head. The cap is sent onto the can mouth by the cap, which rises and presses the can mouth. Pre-sealing and subsequently actual sealing are carried out by the sealing wheel. The pounding head of the cap pushes the can out once it has been sealed.

How To Make Can Filling Machine Precise

• Regular Inspection of the can filling machine
• Wear parts should be checked and replaced on a regular basis.
• Maintaining a stock of high-wear parts Lubricating the machine

Common Application Of Can Filling Machine

• Sauce
• Juice drinks
• Beer
• Energy drinks 
• Coconut milk, walnut milk
• Hydrogen peroxide water
• Mineral water

Bottle Filling Machine 

The bottle filling machine is without a doubt the most crucial component of the entire bottling operation. Because this component is the only machine that has a direct touch with the completed product, it must provide the highest level of hygiene and product quality. 

What Is it A Bottle Filling Machine?

Bottle filling machines are equipment that is used to fill liquids or powders into bottles. These machines are very critical tools in the packaging process of a variety of industries, that includes pharmaceuticals, chemicals, agriculture, and food.

Working Principles Of A Bottle Filling Machine

Liquid items to be packaged can be frothy, dense, creamy, fluid, powder, or granules during the packing procedure. Bottles, vials, pots, jars, cans, tanks, buckets, tins, bags, sacks, or bag-in-boxes are some of the specific packaging types used.

Volumetric fillers with batching syringes, gravity fillers with electronic or mechanical weighing equipment, and negative pressure fillers at constant levels are all used in different filling procedures for example negative pressure, gravity, and isobaric are suitable only for very rigid recipients. To ensure flawless functioning and remarkable precision, the machines are set and calibrated.

How To Make Bottle Filling Machine Precise And High-efficient

• The bottle filling machine should be inspected on a regular basis.

• On a regular basis, wear parts should be checked and replaced.

• Keeping a supply of high-wear parts on hand 

• Keeping the bottle filling machine lubricated

Common Applications Of Bottle Filling Machine

Packaging for pharmaceuticals: The packaging of liquid pharmaceutical goods is critical to the industry’s success. The liquid bottle filling machines provide perfect functioning, resulting in bottles that are user-friendly and free of pollutants.

The machine can be used in a variety of ways: Many local pharmaceutical enterprises are employing these machines to process vial filling, tube filling, powder filling, and syringe filling in order to package their products in unique ways.

Cosmetics and food manufacturing: Syrup, oil, and other liquid items can be efficiently sealed with liquid filling machines. The food business is reinventing its packaging process, as evidenced by milk bottles and grape wine bottles.

Pouch Filling Machine 

Source: Levapack

Alt: Premade pouch packaging machine

End users can effectively fill pouches through the spout on these pouch-filling devices. Technology for pouch filling has been developed specifically for the flexible packaging industry. 

What Is A Pouch Filling Machine?

The goal of using a pouch filling machine is to have a thorough understanding of the product in order to control its flow into the pouch with the highest degree of precision. To choose the optimal filling technology and achieve the greatest outcomes, various aspects must be considered. The more the machine maker learns about the product, the more likely they are to assure the optimal technology option, constant flow characteristics, and appropriate dosing for the brand owner’s product.

Working Principles Of A Pouch Filling Machine

Powders are typically dosed with an auger filler, which is a dispenser that continuously delivers a predetermined volume of product. By controlling the precise number of times the auger screw turns per cycle, the dosage can be adjusted electrically. Because these types of fillers assess the quantity of product per dose by volume rather than weight, the granular settings have an impact on filling accuracy.

The first important guideline of accuracy is to make sure you’re working in a stable setting. To put it another way, it’s critical to maintain a constant quantity of product in the dosing equipment’s “hopper,” which is the cone-shaped container that stores granular and powdered ingredients. Special detectors that can measure the level of product retained inside the auger filler synchronize the feeding system with the auger filler.

How To Make Pouch Filling Machine Precise

• Inspections of your pouch filling machine should be done on a frequent basis.

• Wear parts should be checked and replaced on a regular basis.

• Having a stock of high-wear parts on hand is a good idea.

• Maintaining the lubrication of your pouch filling machine

Common Application

• Snacks
• Fruits
• Nuts
• Cereals
• Coffee beans
• Cosmetics

Automatic VS Semi-Automatic VS Manual Filling Machines

An automatic filling machine. In an automated bottle packing line, such as a filling, capping, and labeling line, an automatic filling machine guides, organizes, fills, and then releases bottles. These machines can be set to fill each bottle with a specific and precise volume of product, therefore, eliminating the need for a filling line operator. Levapack filling machines fill bottles swiftly and accurately with an accuracy of less than 0.5 percent. 

An automatic filling machine is a gate system that automatically organizes the bottles on the conveyor. Immediately when the filling timer runs out, the Auto-FillTM will automatically release the already filled bottles and send them to the conveyor. This will be followed by a new batch of bottles to be filled.

Semi-automatic filling machines. They are appropriate for low- to medium-volume operations. They provide filling solutions that are quick, precise, and adaptable. Good operators can produce up to 40 containers each minute, and switching from one product to the next only takes a few minutes. 

The majority of Universal’s semi-automatic filling devices just require compressed air. Semi-automatic filling machines can fill practically any liquid, from free-flowing scents and alcohols to viscous syrups and adhesives, and even particles-containing liquids like food products.

Semi-automatic liquid fillers can be built using the same filling principles as automatic liquid fillers. That simply means that semi-automatic machines can perfectly use an overflow principle, gravity principle, piston fill, and other automatic production methods.

Manual filling machines. They are operated by hand and do not require any electricity. They’re perfect for small-scale production, laboratory use, and other situations where an external power supply isn’t available or trustworthy. 

Manual filling machines can fill a variety of items, ranging from free-flowing liquids like fragrances and spirits to medium viscosity liquids like shampoos, lotions, and light creams. Filling speeds of up to 15 bottles per minute (900 bottles per hour) are possible with bottle sizes ranging from 5ml to 600ml.

How To Choose The Right One

To begin, there are numerous elements to consider when selecting a liquid filling machine, including overflow, gravity, pistons, and pumps, and selecting the proper machine also depends on your goals. 

One of the first questions to ask when selecting a liquid filling machine is what product or goods are being bottled. Different filling machines are capable of handling different liquid viscosities. Levapack has different options for all your filling machine needs. Go to https://www.levapack.com/about/ and consult for a better decision.

Conclusion

There are several types of filling machines, so it’s vital to keep track of the specifics of the filling machines you’ll need in your area of business. This will assist you in making decisions and purchases. Choosing the ideal filling machine will help in performing efficiently and productively. Contact us if you have any inquiries or you need to purchase quality filling machines.