A manufacturing business that has a production line that includes the bottling of liquid products has five stages: product manufacture, bottling, capping, labeling, packaging, and dispatch.
A liquid filling machine is designed to fill a controlled volume of liquid product into pre-manufactured containers. The technology has evolved to handle many materials, from highly viscous creams to volatile solvents. It works with containers of most shapes and sizes.
The extent of the available designs can cater to almost any production need. These include manual tabletop models to automated high-speed rotary machines.
10 Applications That Use Liquid Filling Machines
The list of applications suited to liquid filling machines is almost endless. There is a machine designed for most liquid products. In this article, we have identified 10 examples that show the variety of applications available.
1. Food and Beverage Industry
The most obvious, and well-known, use of liquid filling machines is in the food industry. This includes all liquid products, such as.
- Honey in all its forms.
- Juices, both fresh and concentrated
- Oils (cooking and natural).
- Syrups (all types with different viscosities).
- Soda drinks.
To protect the product’s brand appeal and also for statutory reasons, liquid food products are required to be bottled in a hygienic environment. Another requirement is that the volumes of product in each package (bottle) be maintained at precisely the same level. The only effective way to ensure these standards are maintained is by using one or more liquid-filling machines.
2. Pharmaceutical and Health Care
An example of the type of liquids bottled by the Pharmaceutical and Health Care manufacturers are.
- Viles Of Volume Controlled Medicines (includes Vaccine)
- Eye Drops
- Prefilled Injections
- Cough Syrup
- Pediatric Solutions
The requirements of the pharmaceutical industry are, arguably, even more stringent than the others. The precision the liquid filling machine are required to operate means that must have “volumetric repeatability.” This means that filling volume levels must be tightly controlled and maintained precisely.
Precision liquid filling machines are set up precisely and they must also be calibrated very accurately. The entire batch will generally be rejected if a single bottle fails quality control. The checks include ensuring that the correct quantity is filled. This is particularly challenging with liquids that contain course-soluble solutions or particles in liquid mediums (suspensions). These create difficulties with controlling consistent and accurate liquid levels in production lines. When looking for a machine in the pharmaceutical industry, it must be designed and built as a precision liquid precision machine. An added burden imposed on pharmaceutical manufacturers is the need for complete hygiene and to operate in a sterile environment.
3. Cosmetics and Personal Care
In 2022 the global cosmetics market achieved a turnover of $262.21 billion. This is projected to reach 4.2% from 2023 to 2030. To maintain this growth rate the most efficient production processes must be employed. The cosmetics and personal care products that are bottled by Liquid Filling Machines include.
- Lotions (Including skin creams.)
- Perfumes (it is very important that the perfumes retain the fragrance)
- Hair Shampoos.
- Hair Conditioners.
- Nail Polish.
Once again, the Liquid Filling Machines have to operate in a completely sterile environment. While the same level of volumetric precision needed by the pharmaceutical industry is not required, it is still important that the product volumes remain consistent. Liquid Filling Machines in the cosmetics and personal care segment generally ensure that each batch has the same quantity. There may, however, be small variations in each container. These are generally difficult to identify and often hidden by the packaging. In this market, the aesthetics of the product container are critical.
4. Chemical Industry
The products that are produced by the chemical industry include the following.
- Swimming pool chemicals
- And other chemicals.
Many of these products are hazardous (either by being volatile or unstable.) The handling of the products must ensure that no additional risk is introduced. One of the methods to achieve this is to keep the human worker’s interaction to a minimum. The process from manufacture, bottling, capping, and labeling should ideally be fully automated. Due to the nature of the product, accurate volumetric measurement is critical.
5. Automotive and Oil Industries
The products produced by the industry that are compatible with liquid-filling machines include
- Motor oils.
- Brake fluids.
- Battery Acid.
- Grease (very viscous.)
- Car washes and soaps.
- Car waxes.
- Leather Car care products.
Some of these products are corrosive and therefore the nature of the products means that the packaging (bottling) must be leak and contamination-proof. Some of the products do not enjoy a high turnover rate, and as a result, the packaging must have the ability to remain sealed for its long shelf life. The bottling must also be able to cope with being handled roughly or bounced around in the trub of a car for long periods. An automated production line that includes liquid filling machines, bottle capping machines, and automated labeling machines is ideally suited to this category of product.
6. Paint and Coatings Industry
The products produced by the paint and coatings industry are ideally suited to liquid filling machines. It is, however, a demanding environment for the liquid-filling machinery because of the different viscosities of the product. This makes controlling the volumes that the machines dispense more challenging. Paint is supplied in hermetically sealed containers to prevent the product from curing before use. They have to be durable and resist damage. Products that can be processed by liquid filling machines include.
- Wood Stain
- Wood Protection.
- Varnish etc.
7. Household Products
The Household Cleaning Products Market in America is projected to increase from $100.50 billion in 2021 to $177.13 billion by 2030. It will achieve an annual growth rate of 6.5% over the forecast period. Part of this growth has been caused by the new attention to household hygiene after the COVID-19 experience. Due to the very high volumes of products produced by the Household Products producers high volume dispensing of domestic household products is a “fait accompli” in this market. The only way the production can achieve this is by full automation, including liquid filling machines. The importance of filling efficiency for mass production is stressed as a non-negotiable requirement. Products that are compatible with liquid filling machines are
- Cleaning agents.
- Liquid soaps.
- Insect repellents.
- Rodent poisons.
- Leather Cleaners
8. Distilleries and Alcoholic Beverages
The alcoholic drink production industry is a key market for suppliers of liquid filling machines. The manufacturing process may often incorporate multiple stages. In some instances, production may take years to complete. The mechanical bottling processes must not interfere with the flavor and quality of the end product. It is essential that the bottles are filled to a consistent level. When the liquid-filled bottles are displayed on store shelves, any variation in quantity will be seen. A sample of the types of liquids dispensed by the liquid filling machines in this environment includes.
- Port etc.
9. Dairy Industry
When it is measured by revenue The American retail dairy market, achieved a $163.6bn in 2022. The market increased by 10.7% in 2022. The only way these volumes can be maintained is by using a fully mechanized production process. This includes liquid filling machines which are used on a massive scale. The liquid packaging line must operate in a completely hygienic environment. Milk includes a variety of product types, along with other essential dairy items:
- Regular milk products.
- Flavored milk and eggnog.
- Probiotic drinks.
- Yogurts (Regular and Greek)
- Butter and other dairy spreads.
- Cheeses and associated cheese items.
- Sour cream, cream cheese, and cottage cheese.
- Milk and whey powders.
- Ice cream.
- Whey processing.
- Evaporated milk.
- Condensed milk
The global size of the Agrochemical industry is expected to grow to 296.6 million metric tons by the year 2030. The challenge with Agrochemicals is their inherent risks that require stringent health and safety protocols. Some chemicals can be corrosive, unstable, flammable, or highly reactive. They might contain potential carcinogens or emit hazardous fumes. The potential for workplace-related injury is substantial. Accidental spills can damage machinery, leading to corrosion and expensive operational breakdowns. Another unique aspect of the Agrochemicals industry is that the products are often dispensed in large quantities into bulk containers. Many standard liquid filling machines are ill-equipped to handle such volumes. Production companies often juggle various products. This means that a variety of container sizes, shapes, and specialized nozzle types are used. The consistency and makeup of chemicals also differ widely. They range from fluid-like consistencies to thicker pastes and suspensions. A further complication is that a single chemical’s properties can shift based on conditions. The ambient temperature, humidity, and other environmental elements can all affect the product. Given these challenges, a liquid filling machine for this sector must be robust and adaptable. Agrochemicals products that incorporate liquid filling machines in the production line include.
- Liquid fertilizers
It is essential that the dosages are maintained very accurately, and therefore, volumetric precision is required,
The Importance of Precision, Efficiency, Consistency, and Cost Control in Industries
It is a mission-critical requirement that a bottling plant achieve the following outcomes.
Where precision equipment is required, the volumes that are dispensed must be 100% precise. This is particularly important in the pharmaceutical industry, where any deviations from the standard may have serious implications. As consumer watch groups become more vocal, it is essential that the advertised product volume is supplied. Only Liquid Filling Machines designed for precision bottle filling are able to perform to the required standard.
For a product brand to survive and even flourish, it is essential that each package must look and feel identical. The customer must be confident that there is no difference between product batches. By ensuring the bottling process remains constant, the brand is reinforced. Equipment designed to ensure “consistency” does not have the same level of exactness as precision Liquid Filling Machines. Machines designed for consistency may not be as precise on a bottle for bottle level. They will, however, be consistent over a batch of bottles. In industries such as food and drink and cosmetics, where the tactile feel of a product influences consumer perception, this is critical. Although meeting regulations is important, it is essential that trust is built with the customer and, ultimately, the end consumer. This is why Liquid Filling Machines have become an essential part of every packaging plant process that produces a product in liquid form.
Time, as they say, is money. Liquid filling machines that can rapidly fill containers boost production rates. This means that they function as an income earner on the company balance sheet, as opposed to a cost center. The production process must run as efficiently and at as low a unit cost as possible. Automating the liquid packaging process with liquid filling machines ensures the lowest unit cost. The ability of these machines to minimize waste and reduce product loss further enhances their value proposition.
All Industry Specific Regulations And Statutes Must Be Complied With
Depending on the industry, the product will need to comply with all legislation related to
- Volume Accuracy
Technologies Used In Liquid Filling Machines
There are several technologies on offer in different liquid filling machines available, such as:
- Positive displacement machines utilize a piston to drive the liquid into the container.
- Gravity-feed machines rely on the liquid’s weight to fill the container.
- Hydrostatic machines use pressure to fill the container.
- Mechanical machines are powered by gears and shafts for the filling process.
What questions should I ask when considering a Liquid Filling Machine?
- Which filling methodology will work with my product?
- Is the filling machine compatible with all of my bottles and containers?
- What production speeds should I anticipate?
- Is the liquid filling machine scalable, and can it grow with the company?
- Is the Liquid Filling Machine compatible with the rest of the production line equipment?
Why opt for XYZ Machinery for a Liquid Filling Machine?
- XYZ liquid filling machines boast advanced safety features, proactively halting operations before potential hazards arise and ensuring user safety.
- Our liquid filling machines incorporate smart technology, featuring an intuitive design coupled with a PLC control system and a touchscreen interface.
- Every component is linked via quick-connectors, simplifying disassembly for easy cleaning.
- XYZ liquid filling machines offer exceptional value at a competitive price.
How Do I Buy A Filling Machine from XYZ Machinery?
- Click on the “Instant Quote” and complete the drop-down inquiry form. We will get back to you within 8 hours to discuss your requirements.