How Does Automatic Filling Machine Work?

Filling machines are designed to speed up the production line, especially for liquid bottling operations. Filling systems come in a variety of designs, ranging from semi-automatic table top versions to extremely efficient automatic multi-head filling machines. 

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The size of your operations and the type of liquid you’re working with are among some of the factors that determine the best filling machine for the job. This guide will introduce you to different types of filling machines and help you decide which equipment is right for your business.

What is a Filling Machine?

Liquid filling machines play a vital part in the production of bottled products, including sports drinks and cleaning solutions. Some filling machines can also handle more viscous substances, like pastes, creams, and chunky products such as sauces or salsa. 

Bottle filling machines are often stainless steel, and range in design from single head manual filling machines, like a tabletop piston filler, to much more elaborate configurations, like a fully-automatic multi-head filling machine with many heads for greater throughput. 

Filling equipment must be selected based on key factors, like the desired speed of production, the type of liquid, and the size of the container being used.

How Does a Filling Machine Work?

The purpose of a filling machine is to efficiently deposit a precise amount of liquid into each container based on time, weight, volume, or a combination of these measurements. The exact way in which a filling machine functions depends on a few factors, like whether your production line is semi-automated or fully-automated. 

With a semi-automated bottle filler, a human typically places each bottle under the machine, but a conveyor belt may assist in this step. A human may also be responsible for deciding when the machine starts and stops releasing liquid into the container. 

Fully-automated filling machines control the entire process. Typically, a conveyor belt brings clean bottles into the filling area where a sensor identifies them. The machine then starts dispensing liquid before moving the containers to the capping and sealing station. More clean bottles are then moved into the filling area and the process repeats.

Can IFS Help Me Customize My Filling Machine?

At IFS, we understand that your operation is likely facing unique requirements, and we are happy to offer our engineering expertise to find the right solution for your production line. 

We offer a wide range of machinery and we can accommodate foaming liquids, hazardous chemicals, food-grade products, and environments where cross-contamination is unacceptable. If you’re interested in speaking with our team of liquid packing experts, give us a call or visit our website.

How Many Kinds of Filling Machines Does IFS Offer?

IFS offers specialized filling machines suitable for a number of different products, including water, gels, creams, and sauces. Understanding the differences between our selection of bottle fillers is important in choosing the right machine for your operations.

While comparing your options, consider viscosity, efficiency, and maintenance requirements. If you don’t know the difference between a volumetric piston filler and a pump filler, the following overview will prove helpful and our team is always standing by to answer your questions.

Overflow Filling Machines

Ideal for liquids with low to medium viscosity, these machines fill a container based on volume. An overflow filling machine is unique in that it uses a recirculation method to fill a container to a given level. The machine inserts a nozzle into each container and fills it to a specific level. During the filling process the machine returns any additional product from the container out to a holding tank for re-use.

Time Gravity Filling Machines

Ideal for thin liquids with consistent flow characteristics, a time gravity filling machine keeps product in a holding tank positioned above the machine’s pneumatically operated valves. This method requires you to calculate how long it takes for your container to fill to the desired level. Containers pass under the valves at set intervals while the filling machine opens the valves to allow gravity to move the liquid from the tank and into the containers.

Net Weigh Filling Machines

Ideal for items sold by weight and high-value products that demand accuracy, net weigh filling machines prevent over- or under-filling by weighing each container as it’s filled. This is ideal for bulk products sold by weight, like 5-gallon containers, and for high-value products that need to be accurately weighed to maintain profit margins.

Peristaltic Filling Machines

Ideal for aqueous and light viscosity products in small volumes, these precision machines also avoid cross-contamination. Product is contained within a tube inside the pump and it is compressed by “rollers” on the rotor. The pressure exerted by each roller pinches the tube closed, forcing product down and out. As the rollers are applied and released, ambient pressure draws fluid into and out of the tube in a process known as peristalsis.

Piston Filling Machines

Ideal for high viscosity liquids and products with particulates, piston fillers accurately dispense product into a container based on volume.  The amount of product dispensed can be easily adjusted by changing the stroke length of the piston. Because of their design, piston filling machines are excellent for thick and semi-solid products, like chunky condiments, cosmetic creams, waxes, heavy oils, gels, and adhesives.

Servo Pump Filling Machines

Ideal for liquid and semi-liquid products, servo pump filling machines are an updated alternative to piston fillers. These machines use an encoded rotary pump that offers accuracy and clean dispensing, even for high viscosity products. Special nozzles can be added to manage specific product properties. Compared to traditional piston fillers, the servo pump fillers offer greater container size flexibility with faster changeovers in sizes with less air use and a Clean in Place (CIP) design capability.

Brine Filling Machines

Ideal for brine and vinegar solutions with and without particulates the filler provides a consistent brine level in the container to cover the product. Because bring and vinegar solutions are corrosive to equipment overtime, brine filling machines are explicitly designed to handle these liquids effectively. They are also capable of processing various parictulates within the liquids without being susceptible to clogs and buildup in the nozzle.

Pail Filling Machines

Ideal for dispensing product into five-gallon pails based on weight or volume, the pail filling machines from IFS are a cost-effective solution to managing pails and lid sealing. The standard pail filler is designed for 5-gallon buckets, but can be customized to meet your needs.

Drum Filling Machines

Ideal for filling totes, 25-gallon barrels, 55-gallon drums, and similar large containers. Drum filling machines can be set up to fill based on weight, volume or a combination of these measures, allowing for accuracy even in large quantities. Configuration options include top-fill or bottom-fill, with top-fill being more economical but not suitable for foaming products. Bottom-fill machines are more expensive, but offer the most versatility.

Why Should I Choose a Filling Machine from IFS?

Inline Filling Systems has been in business for over 25 years and has the widest selection of filling equipment with more than 700 types of machinery in our extensive catalog. Our team manufactures and services all of our equipment from our factory in Florida. 

When you choose a filling machine from IFS, you’ll benefit from expert service, advanced customization options, and superior machine maintenance. Whether you’re a small operation seeking a semi-automatic solution or a large operation in need of a fully-automatic process, we have the knowledge and equipment necessary to fulfill your needs.

Filling machine plays a crucial role in the packaging industry, ensuring accuracy and efficiency in filling containers with various products. This article explores the definition and functionality of various types of machines used for filling and how they operate to achieve the desired outcomes.

Considering that machinery is a sizable investment for any business, you need to know the ins and outs of how it works. Read on to ensure you make an informed decision.

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What is an Automatic Filling Machine?

These machines do precisely what they say — they fill containers with products (accurately and efficiently). Depending on their design, they can handle different types of products, including liquids, solids, powders, granular items, and semi-solids.

Because of their versatility, they are commonly used in the food and beverage, pharmaceutical, chemical, and cosmetics industries. However, packagers can choose either manual or automatic versions, with the latter being faster and more precise. 

Types of Machines for Filling

Several machines are available, each catering to different product types and filling requirements. Some of the most common types of filling equipment include:

Powder Machine

It is explicitly designed for containers with powdery substances, such as spices, flour, or pharmaceutical powders. An auger or impelling system is typically used to control the powder's flow.

Solid Machines

Perfect for filling containers with solid items such as tablets, capsules, or candies. These machines usually employ a mix of vibration and mechanical sorting systems to ensure accurate product placement.

Liquid Filling Machines

They are crafted to fill containers with various liquid products, like beverages, sauces, and chemicals. These machines utilize diverse filling mechanisms to accommodate the liquid's viscosity and flow properties. 

Pouch Machines

Designed for filling pre-made pouches or bags with various products, including liquids, powders, or solids, they often combine filling and sealing mechanisms to produce a finished product.

Bottle Machines

Created for filling bottles with various products, from liquids to powders to solids. These machines frequently incorporate capping and labeling functions as well.

Jar or Tin Machine

Ideal for jars or tins with products such as jams, preserves, or creams. A jar-filling machine typically employs a piston or pump filling system, guaranteeing precise and consistent filling.

How It Works

Filling machinery operates through a series of steps to ensure the accurate filling of containers. Here is a general outline of the process:

1. Container loading

Containers are loaded onto the machine, either manually or automatically, depending on the machine's configuration.

2. Container positioning

The machine aligns the containers to ensure proper filling. This step often involves using guide rails, belts, or conveyor systems.

3. Filling process

The filling mechanism, such as a pump, piston, or gravity system, dispenses the product into the container. This process can be continuous or intermittent, depending on the machine's design and the product being filled.

4. Filling verification

Sensors or other verification methods employed by the filling machine manufacturer ensure that the correct amount of product has been dispensed into each container.

5. Container sealing

If applicable, the machine will seal the container using capping, lidding, or heat sealing methods.

6. Container discharge

Once filled and sealed, the containers are discharged from the machine and moved on to the next phase of the packaging process, such as labeling or palletizing.

Different Filling Mechanisms

These machines employ a variety of mechanisms to transfer products into containers. Some widely-used filling mechanisms are:

Gravity fillers

These fillers rely on gravity to distribute the product, making them perfect for free-flowing liquids. The liquid filling machine fills containers to a predetermined level, ensuring precise filling, while any excess product seamlessly flows back into the supply tank.

Pump fillers 

Ideal for liquids with differing viscosities, pump filling systems utilize a pump, often controlled by a servo motor, to accurately dispense the product into the container.

Piston fillers

Piston fillers draw and release the product using a piston mechanism. This filling system is well-suited for products with a broad range of viscosities, including thick pastes and creams.

Overflow fillers

Designed to fill containers to a specific level regardless of container size variations, overflow filling systems are ideal for thin, free-flowing liquids and guarantee a consistent fill level across all containers.

Bottom-up pressure fillers

This filling technique positions the nozzle at the container's base and raises it while filling. It's suitable for foamy or viscous products, as it minimizes air introduction and agitation during filling.

Final Thoughts

Fillers are a critical aspect of the packaging process, ensuring efficient and accurate filling of containers with various products. 

Selecting the right filling machinery for your packaging needs depends on the type of product, its viscosity, and the specific packaging process requirements. It's essential to understand the various types of filling systems and mechanisms to choose the best solution for your business.