There are many types of filling and sealing machines used to package the variety of products in today's marketplace including liquids, pastes, chunky products, powders, granules, tablets, capsules, etc. Most filling machines are available from semi-automatic tabletop versions all the way up to high speed production line machines, including rotary fillers. Even within categories of filling machines there are often many choices available, so we always encourage you to call or email us to make sure you are buying the exactly correct machine for your application(s). This article mainly introduces the types of liquid filling machines.
There are usually different filling types according to different filling standards.
According to the degree of automation, the types of filling machines are: manual filling machines, semi-automatic filling machines, and fully automatic filling machines.
Fully Automated Filling Machines
These are used for large-scale operations and in companies with high production needs. Automated filling machines are generally used with variable speed conveyor systems and for packaging, liquids with all levels of viscosity and those with suspended particles. Some manufacturers also configure their automated machines based on the type and volume of the filling container you are using for your product. You can also add filling heads on the machines to boost your company’s production rates. Automated cup filling and sealing machines can fill 5-10ml of a product and generate 6000 bottles/hour. We mainly produce this type of machine.
Liquid Level Filling Machines
Siphon Filling Machinery
The simplest and probably one of the oldest technologies devised by man was the siphon principle. In this case we are talking about the siphon filling machinewith tray sealer. Gravity flow into the tank to a valve that keeps the liquid level even, put some gooseneck valves up and over the tank side and back below the liquid level of the tank, start a siphon and voila, you've got a siphon filler. Add to that a little extra framing, and an adjustable bottle rest so you can set the fill level to the level of the tank and we now have a complete filling system that will never overfill a bottle, with no need for pumps etc. Our siphon filler comes with 5 heads (size is selectable) and can produce quite a bit more than many think possible.
Volumetric Filling Machines
Check Valve Piston Filler
Check valve piston filling machines use a check valve system that opens and closes on the infeed stroke and discharge stroke. A great feature of this type of filling equipment with can seamer is that it can self prime to draw product directly from a drum or pail and then discharge into your container. Typical accuracy on a piston filler is plus or minus one-half percent. However check valve piston fillers do have certain limitations in that they cannot run viscous products or products with particulates as both can foul the valves. But if your products are free flowing (meaning they pour relatively easily) this is a great machine for startups and large producers as well.
Pump Filling Machines
Pump fillers are another method of filling products ranging from liquids to thick pastes, even those with solid particulates (although generally much smaller than on a Rotary Valve Piston Filler). Available as tabletop models through multi-head ganged automatic machines. Another advantage of using positive displacement pump filling equipment is that the range of fill volumes is much greater than on a piston filler, albeit that the fill times increase significantly the larger the fill volume required. Other great features of a pump filling machine include easy fill adjustment by entering the amount needed, and a self priming feature similar to a check valve piston filler's ability to draw product directly from a drum or other container. For thicker products a supply hopper can be added similar to a rotary valve piston filler so that product flood feeds directly into the pump. Fill volumes are determined by counting revolutions (and partial revolutions) of the pump. There is also manual can seamer to use.
Pressure Fillers:
Pressure filling machines, or automatic can sealing machine, have their tanks below the bottom of the bottle. The tank flood feeds a pump (generally a centrifugal pump but also positive displacement pumps for thicker liquids) which then flows directly into the bottle until it reaches the fill level at which point excess product flow directly back into the tank. When filling plastic bottles the pump must be turned off (always for positive displacement pumps) before removing the filling tubes to allow the bottles to return to normal size (they swell under pressure) and drain off excess liquid. The big advantage of pressure fillers is that bottles fill more quickly so fewer heads (and space) are required and higher viscosity products can be filled. The disadvantage is that foamy products must be filled at slower pump speeds than normal, and this will work only if the foam settles out fairly quickly.
Counter Pressure Fillers:
These are liquid filling machines with labeling machine, or label sticking machine, unique to the carbonated beverage industry which includes beer, soda and any sparkling beverage or wine. NPACK does not sell counter pressure fillers, but we will still explain this complicated type of filler. The heads for this type of filling consist of 3 parts: Vent, CO2 pressurizer and fill tube. The head seals and the Vent and CO2 pressure valves are opened. The air in the bottle is forced out of the bottle and is replaced with the heavier CO2. The vent is then stoppered down and product from very specialized heads forces the chilled carbonated liquid down the sides of the container in a sort of swirl pattern to minimize foaming. Once the fill height is reached the vent completely closes at the same time the product is cutoff. Many people mistakenly think that the CO2 counter pressure is the carbonating process, but carbonizing is a bit more complicated than that. The purpose of the CO2 is to keep the already existing carbonized beverage in solution and to minimize foaming.