There are a large number of factors that may be considered when selecting the right filling machine for the packaging system. Production rates may have an effect on the automation measure of the machine. The quantity of available space may force a packager to consider a tabletop or monoblock filler rather than an inline filling machine. But with regards to the filling principle for use for virtually any given project, the viscosity in the products being filled will often be the main step to consider.
Viscosity is described as their state or quality being viscous, which, admittedly, is not very useful. It may also be understood to be a liquid’s effectiveness against flow, which clears things up a bit. In general packaging terms, viscosity can be considered to be the thickness of any given product and also the ability of that product to circulate freely. The less viscous the merchandise, the more likely it is going to be a thin, free-flowing liquid, like water. The greater viscous something, the much more likely it will be a thick product which does not pour, or flow, freely, such as paste or putty. Thin, low viscosity products will normally demand a different filling principle than thick, high viscosity products.
The two main forms of supplies gravity filling machine that will normally work nicely for low viscosity products, or those found near the top of the above chart. The initial one is called an overflow filling machine. These liquid fillers use special nozzles that allow for the level fill on each bottle, even if the interior number of each bottle varies slightly. The nozzles of the overflow filler will descend to the bottle and release product like a seal is generated over the bottle opening. Once the product reaches a specific level inside the bottle, the liquid “overflows” via a return port returning to the supply tank, leaving the consistent, level fill in each container. As you may expect, overflow fillers are popular with water and other free-flowing products which are packaged in clear containers. The amount fill helps create an aesthetically pleasing shelf presence for bottles along with other containers as soon as the item is visible.
The next type of filling machine which could commonly be located in a facility packaging low viscosity products will be the gravity filler. These filling machines load product into bottles and containers employing a time based system. Generally, a gravity filler includes a tank held over the fill heads to offer the product. Once containers will be in place beneath the fill heads, fill valves is going to be opened to get a pre-set timeframe, allowing product to circulate into the bottles. When the time elapses, the valves close and the product supply is cut off. These economical filling machines use, as the name applies, gravity to assist in the filling process.
As products become a little more viscous, these filling principles become harder to apply. Free-flowing items are essential to efficiently and consistently fill bottles while using overflow filler and gravity filler. A slower moving product requires a little extra push to go it throughout the product pathway and to the bottles. Typically, there also exist two filling principles for high viscosity products, or those seen at the bottom of the above chart. The very first form of filling machine employed for thick products can be a pump filler. These liquid fillers make use of a single pump for every fill head found on the machine. The sort of pump used is determined by the specific product characteristics along with the production requirements of your particular project. Pump filling machines gravvity be time based, meaning the pump will turn on and off for a pre-set amount of time each cycle. Within the alternative, these fillers might be pulse based, and therefore the pump will rotate or turn exactly the same each cycle. By way of example, in case a gear pump is used about the filling machine, each pulse may be a quarter turn of the gear.
The next alternative for thicker, high viscosity products is actually a piston filling machine. These machines provide highly accurate volumetric fills with the use of a piston and cylinder. As being the piston pulls out from the cylinder, product will enter and fill the cylinder. Once full, the piston re-enters the cylinder, pushing the product out to the waiting bottles. The accurate fill comes from the point that the cylinder holds a similar volume of product every time the piston retracts, thus pushing the same amount of product during each fill cycle as well. An additional advantage of the piston filling machine is that the open cylinder allows the device to take care of products which include particulates or chunks, like salad dressings, or fruit jams and jellies.
Even though the general rule above holds true most of time, there will be situations once the different filling principles will probably be used outside of the norm. By way of example, several larger companies fill several product for his or her consumers. These multiple products may run the gamut from low viscosity to high viscosity. When this happens, a piston or pump filler are often used to fill both thick and thin products. In some cases, where production rates dictate, two separate filling lines could be developed for two separate kinds of products. While viscosity plays a sizable part in locating the optimal filling principle for almost any given project, each project may also be unique in its own right and may require custom filling solutions.