Filling machines are just a small but significant section of packaging machines. Therefore, having the right one can lift the packaging process and simultaneously add substantial worth to the overall business. Selection of the relevant filling machine is crucial for many industries, where the practice of dealing with materials of variable viscosities is common. Viscosity is the most essential consideration component when choosing the filling machine. It is evident to understand the nature of materials to opt for the right one for your enterprise.
Viscosity, which is defined as the resistance of any substance to flow, is a fundamental property influencing the flow behavior of products. In broader terms materials or liquid products are classified into two types:
- Low-Viscosity Materials
- High-Viscosity Materials
Low-viscosity materials are easy to flow with a thin consistency, whereas high-viscosity products are thick and show more resistance in flowing. Therefore, proper choice of filling machine is essential to accommodate a wide range of viscosities along with ensuring accuracy, precision, reliability, and efficiency. Hence, this formal guide is prepared by keeping these factors in mind and to provide you with basic knowledge and understanding of the process of selecting the appropriate filling machine based on the respective viscosities of the materials to be filled.
Ⅱ. Types Of Liquid Filling Machines
There are many types of filling machines available in the market. And with the advancing technology, the numbers and types just keep on increasing to meet the existential demands of the industries. Only the needs and requirements of the industry product can help select the perfect liquid-filling machine for the business. The liquid filling machines can broadly be classified based on automation and the nature of the liquid fillings.
Based on automation, a liquid-filling machine can be
- Manual Filling Machines
- Semi-Automated Filling Machines
- Fully-Automated Filling Machines
1, Manual filling machines
As the name suggests, these kinds of filling machines are manually operated and require no extra usage of energy or power. Mostly used for high-viscosity to medium-viscosity materials such as creams, pastes, gels, shampoos, etc. Precisely suitable for small businesses or laboratories where precision and accuracy are achieved by hand pouring. The machines only aid in increasing the production output speed.
2, Semi-Automated Filling Machines
Faster than the manually operated filling machines, these types of machines are used for handling small to medium-scale productions. Can be used for all types of liquids, even materials containing small food particles.
3, Fully automated filling machines
These kinds of machines are fully Automatic and require the use of Energy and Power. Required by large enterprises where the demand for production speed and output rate is very High. Designed to handle materials of various viscosities and is even able to handle suspensions. According to the type of fillers, a liquid filling machine can be of the following types:
- Gravity Fillers
- Piston Fillers
- Molten Fillers
- Pump Fillers
- Inline Fillers
- Net Weigh Fillers
- Pressure Fillers
- Rotary Fillers
● Gravity Fillers
Foamy and thinner liquids are mostly filled by gravity fillers. The principle of working a gravity liquid filling machine is to transfer the bulk amount of material into the tanks or holding vessels where they are set above the valves. The valves are Air Pressure controlled and regulated with definite fill time. Such as water bottles filled with gravity fillers.
● Piston Fillers
Materials like sauces, batters, icing, creams, etc, are filled by Piston Fillers. They cover a wide range of materials and are ideal for accurate filling while being versatile as well. More often their usage is highly applicable for high viscous materials.
● Molten filler
Molten fillers are used for materials that require hot filling and then they will be cooled afterward. However these products should not only be kept hot but must be maintained within a very definite certain temperature. If the temperature conditions are not consistent then it will cause issues like improper filling, pullged products pathways and even causing problems within the filling machine. Meanwhile, Molten Fillers are specially designed to handle Hot materials and are used for filling Candles, Soap, Lip Balms, Deodorants, etc.
● Pump Fillers
Pump fillers are the most ideal type of liquid filling machines. These types of machines can handle all types of viscosity of the materials. Their versatility and accuracy make them ideal for use in any industry dealing with liquids. The pumps can further be classified into different types that are used in industries.
● Inline Fillers
Containers requiring filling along the single file line across the conveyor system use these kinds of fillers. Able to handle liquids and Semi-liquids of variable viscosities. Maximizing the filling efficiency, these kinds of fillers are mostly used by Small businesses to increase their filling accuracy and precision.
● Net Weigh Fillers
As the name suggests, these kinds of fillers are used where the containers are filled in bulk quantities and make sure that each container contains the same amount of material. Also used for High-Value materials where wastage is costly.
● Rotary Fillers
Rotary filling machines are used where the filling and packaging process is in circular stations, where each station is designated for different functions such as Filling, Capping, Sealing, etc.
● Pressure Fillers
Works the same as gravity fillers the only difference is that their use of pressure for filling makes them appropriate for high-viscosity liquids.
Ⅲ. Types Of Pumps Used In Filling Machines For Handling Different Viscosity Materials
Many industries deal with materials of variable viscosities and to accommodate their requirements and needs there are various types of pumps used in filling machines. These types add up to the versatility of the filling machine and handle liquid with different viscosities. The most common types of pumps that are employed in filling machines are:
- Gear pumps
- Lobe pumps
- Peristaltic pumps
- Piston pumps
- Cavity pumps
Let us discuss these one by one.
● Gear Pumps
These kinds of pumps are suitable for high-volume filling such as chemicals, oil containers, etc. They can handle low to high ranges of viscosities and are more economical among others.
One great advantage of a gear pump is the speed of filling, hence used for high-volume filling containers.
● Lobe Pumps
Lobe pumps are high-pressure pumps and are suitable for Shear–Sensitive liquids. They can deal with low to high ranges of viscosity and are more appropriate for dairy products and pharmaceutical use. Lobe pumps are used for clean and accurate filling solutions for materials like food and personal care. Their sanitary and accuracy feature makes it an expensive pump but it is worth every penny.
● Peristaltic Pumps
Peristaltic pumps are ideally used in industries where there is a risk of contamination, especially Biomedical and Pharmaceutical industries. They provide a simple setup and a filling accuracy. It can handle a viscosity range of low to medium and is mostly used for medium to moderate fillings.
● Piston Pumps
Piston pumps are ideal for industries where accuracy matters the most. They provide pinpoint accuracy with no slight difference. Appropriate for usage in the food and beverages industry as well as chemical industries. They are easily manageable and show no technical difficulty.
● Cavity Pumps
Cavity pumps are suitable for variable viscosities ranging from low to high. Especially those liquids that contain solids. Widely used in food industries.
Ⅳ. Key Considerations While Choosing The Liquid Filling Machine
Opting for the right liquid filling machine for your industry can bring an immense amount of benefits and advantages to the business. From precision to efficiency and productivity to speed, every aspect gains a boost to profit the entire business. However, selecting the right one can be a little challenging especially if you have to deal with different viscosity ranges in filling equipment. Here are some key points that you should consider when choosing the liquid filling equipment for your industry.
1, Range of viscosity
The nature of the material should be the very first aspect of consideration. The nature of the material will decide which machine or equipment is suitable for your business. There are liquids ranging from Free-Flowing to Highly viscous Semi-Solids type. Hence, there are different machines available to handle different ranges of viscosities. However, fitting certain pumps or nozzles can help you deal with different viscosity ranges within the same machine but will require extra bucks. Therefore, choose as per your needs and requirements.
2, Type of Containers
The type of container is another important aspect in choosing the liquid filling machine. You need to be sure that the machine you are picking will be able to fill the type of containers you use; i.e. Long or short, wide or narrow, cylindrical or square, glass or plastic, and many more types. Some machines can handle the variety whereas some machines cannot! Therefore it will be as per your needs and requirements whether you want versatility or not.
3, Maintenance and Cleaning
Maintenance and cleaning is the most important factor for choosing any equipment. Since the efficiency of any machine depends upon its maintenance and cleaning. For choosing a filling equipment is evident because of higher chances of buildup which can result in low efficiency and lesser output. Therefore, always opt for machines that are easy to disassemble and clean.
4, Compatibility with the Material
As you will be choosing liquid filling equipment, it is essential to consider the compatibility of your product material with the machine parts. You should opt for machines whose parts are resistant to corrosion and do not corrode with the contact of your liquid material. Otherwise, it will affect the overall efficiency of your output and decrease productivity along with the extra burden on your budget scale.
Integration of your chosen filling equipment with your existing industrial plant is essential for the equipment to work best in your favour. If your chosen machine doesn’t integrate with your existing industrial plants then it can cost you extra money to fix the integration. However, many manufacturers’ machines are easily integrated into large industrial plants to avoid any extra cost and time. Although it’s always wise to consider before choosing it!
6, Budget Concern
Quality is the main aspect and you should never compromise on it! BUT essential to look up to your budget constraints. Finding a balance between your needs, requirements, features and the cost of the equipment will help you choose the best for your business and industry.
7, Speed and Accuracy
It is another important aspect that needs to be considered before buying any machine. For example: How much speed do you need? Do you require high-volume filling or low-volume filling? Do you need to fill in bulk or not? Do you need pinpoint accuracy with your fillings or a slight difference can be okay? All these questions are necessary to answer before choosing the filling equipment. Every filling equipment is manufactured to cater the specific requirements.
8, Adaptable to Industry Standards
Regulated sectors like food, beverages, and pharmaceuticals have high industrial standards. Your opt-filling machine needs to meet the industrial standard to work efficiently within the field.
Hence, a machine only works best for you if it can meet your standards and demands.
9, Customer Support
The customer support area of consideration is applicable for any kind of equipment you need to buy, not just the filling equipment. The machines have many technical difficulties while adjusting and even afterward as well. One will only be able to handle it with good customer support. Therefore choose buyers who are experienced in their work and provide good technical support throughout your usage.
10, Trial Period
It is better to have a trial period before making an investment. Therefore, if you are a First-Time Buyer or a regular user, do consider having a trial period of the equipment to rule out all technical difficulties and make sure whether the equipment is worth the investment or not.
Ⅴ. Why Choose Xyz Filling Machinery
XYZ Filling Machinery is one of the most trustworthy companies to buy equipment for your industrial and business needs. There are several reasons why XYZ filling machinery is best for all your industrial needs.
- A team of highly qualified professionals and manufacturers
- The parts used in machines are all branded and of top-notch quality.
- Machines are manufactured as per the latest technological advancements
- Wide range of machinery available to choose from
- Good customer and technical support
- Highly experienced maintenance team
In summary, it is essential to have a basic knowledge of the equipment before buying it. When it comes to liquid filling machines, various variables are involved to consider to keep yourself safe from overspending and constraining your pockets. It is better to understand your needs and requirements while searching the market for the best equipment.
XYZ filling machinery employees make sure to provide their customers with complete knowledge of the equipment and completely understand the needs of their customers for the provision of top-quality services and products.