Different filling machines use different mechanical methods to fill containers with the correct amount of liquid in a clean and efficient manner. There are four main filling machine principles &#; gravity filling, overflow filling, piston filling and pump filling. While these filling machines can all handle a range of products, especially with customization, the best system for your business depends on the characteristics of the liquid you are packaging.
For lower viscosity or frothy liquids, gravity filling is often a simple and economical solution. This filling principle operates by storing the liquid above the bottles to be filled and allowing gravity to draw the liquid down. For this to work smoothly, the liquid has to be free-flowing with a consistent viscosity, and it should not have any particles that could obstruct its movement through the machine. This system works on the volumetric filling principle, dispensing the same amount of liquid each time using a timed fill.
This filling machine principle is well-suited to a wide range of industries, including food and beverage, specialty chemical and cosmetics and personal care, so long as the product is free-flowing and of a low enough viscosity.
The overflow filling principle stands out for its ability to fill bottles to the same level, even if that results in slight variations in volume. For retail products packaged in clear containers, this visually-appealing evenness is an important way to appeal to your customers. Without this system, slight variations in the interior shape of your containers could make it look as though your products are filled unevenly, even when they are not. Your customers may reject a bottle that looks as though it contains less than the others, which could result in unsold units. Maintaining an even fill-line prevents this perception, while also looking more professional.
Overflow filling works best with thin to medium viscosity products, and this method can fill bottles at a fast rate. Any leftover product left in the filling tubes is pushed back into the storage tank to prevent waste.
Piston filling systems are suitable for liquids ranging from thin viscosities to thick. They are also able to process semi-solids and liquids with particulates. They pump product into containers in very precise amounts, delivered from a bulk tank that can also be configured with a buffer tank utilizing a level-sensing float, a manifold with directdraw, or recirculation methods. Apex offers different models of piston fillers suitable for high-volume industrial needs, startups seeking more economical models, and table-top semi-automatic enterprises. We can also customize your equipment to make filling even more efficient, such as adding a heated hopper to a tabletop piston filler to warm up thicker liquids, making them flow more easily.
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Piston fillers are especially well-suited for higher-cost liquids that need to be dispensed in precise amounts with little waste, such as pharmaceuticals, essential oils, and THC and CBD tinctures.
Pump fillers are the powerhouses that can move even the thickest products, including those that drip, stretch or contain large chunks. But while pump fillers are known for working well with substances like honey, salsa or car wax, they can also handle watery, low viscosity products just as well. This type of system also permits an easier change between different fill volumes, which is more convenient for a single operator who needs to fill containers of different sizes.
As with piston fillers, pump fillers are available in industrial models as well as semi-automatic tabletop systems for new and growing enterprises.
All of the filling principle systems we offer can be adapted for sanitary, corrosive, flammable and hazardous products. In addition, we have the expertise and dedication to work with you to find solutions that meet the specific needs of your business. Call us and let us know what type of product you need to fill, and we will help you find the best system for making your business more profitable.
Apex offers all of our clients customized solutions to their filling needs. To learn which filling principle is best for your business, call us at 219-575- or visit our page here.
Integrity, honesty, and a dedication to delivering ambitious results serve as the central themes of Alicia&#;s career and are evident in every interaction she has with our clients. Her relationship-centered leadership style has paved the way for Apex Filling System&#;s culture of compassion & empathy, executed with accountability that ensures consistently great outcomes. As a learner for life, her pursuit of continuous personal and professional growth has led Apex Filling Systems to be recognized as an industry innovator in customer experience. Holding advanced degrees in the areas of engineering and management, she has a unique ability to analyze processes, identify potential problems before they arise, and develop standardized solutions to ensure every client of Apex Filling Systems enjoys a hassle-free, professional, and pleasant experience. Her leadership style has been influenced by the work of some of the most well-regarded thought leaders throughout the last 50 years. Among them are Jim Collins, Sally Hogshead, John Maxwell, and Tony Robbins.
Gravity filling is the simplest filling method. The uncomplicated construction and operation of gravity filling machines permits them to run with a minimum of maintenance. The supply tank (more properly called the filler bowl) is the upper, central part of the machine. Filling stems are attached to the bottom surface of the bowl at each container filling point. A vent tube extends upward into the filler bowl to a point above the liquid level. To begin the filling operation, the container is raised by the platform until it contacts the filling stem. The platform then continues to raise the container against the stem, opening the filling valve. With the filling valve open, the liquid drains into the container. The air in the container flows out trough the vent tube into the space above the liquid in the filler bowl. Although the container becomes filled, the liquid continues to flow in. The excess fluid rises in the vent tube until it reaches the same height as the liquid level in the bowl. Because the vent tube extends above the bowl liquid level, there is no overflow of liquid from the container into the bowl. If the product is foamy, the foam will rise in the vent tube above the liquid level in the bowl. If it is stable foam and will not break down, it will ultimately overflow into the bowl. For this reason, gravity fillers are not often used for foamy products. At the predetermined time after the container is filled, it is lowered from its filling position, closing the filling valve. Liquid left in the filling stem is removed from the vent tube in several ways. For most applications the liquid will fill drain into the next container. For high viscosity (thick) liquids, the vent tube is usually brought out beyond the side or top of the bowl. Here its outer end can be connected to a device that applies pressure or vacuum to the liquid in the tube to assist in the liquid removal. The total differential pressure that allows the fluid to flow is caused by the gravity head pressure in the bowl. This is usually no more than two or three feet of head, or about one psi. On this basis, it can be seen that these fillers will not permit rapid filling of viscous liquids unless they have larger diameter filling stems. To accommodate the stem, the container must also have a large neck opening; otherwise machine modifications have to be made. ElGravity 150×150 Gravity Filling Machine PrinciplesAnother type of gravity filler uses electronics. It consists of a fixed liquid reservoir or bowl with open-end filling stems. The containers are conveyed on the filling line with an intermittent motion, stopping beneath the filling stems. Inside each filling stem is a ball check connected to a long rod. A pencil shaped magnetic block is attached to the top of the rod and passes through a magnetic coil. As the container moves under the stem, it is detected by a sensing device such as a limit switch or electric eye. This device stops the conveyor, and energizes the magnetic coil. The magnetic field causes the magnetic blocks to lift, raising the rod and the ball check from its seat inside the stem. The rate and amount of fill is controlled by the size of the stem orifice and time delay relay connected to the magnetic coil. Because a direct insertion filling tube is not used on this type of gravity filler the filling stem orifice must be smaller than the inside diameter of the container being filled. On small size containers a more positive means for positioning the bottle beneath the filling stem is used. Fill Height Control In addition to controlling fluid flow, control of the filling height is also important. In general filling machines that elevate the container control the fill height from the bottom of the bottle to the liquid level. The rise of the container is positive, and variations in overall container height are compensated for by greater or lesser seal compression. On rising container machines, a compression spring is often built into the tray elevating mechanism. In this case, container height variations are compensated for by the spring, and the fill height is then controlled from the top of the bottle to the liquid level. Controlling the fluid level from the top can be important if the bottle to be filled has square shoulders, because even a slight under fill is noticeable. In rising stem fillers, variation in container height is taken up by the stem itself. It is usually lowered by gravity or light spring pressure, so the fill height is controlled from the top of the bottle to the liquid level. If the product contains a volatile liquid, such as alcohol, control of the fill height is especially important. In this instance, excessive headspace could allow dangerous vapors to form and the bottle would possibly burst if it were stored in a hot warehouse. Therefore, controlling the fill height is an important function of the filling machine. Normally, a fill height tolerance of 1/32&#; is acceptable. Container Control There are several devices used to control the containers coming into the filling area. Included are star wheels, worm or screw sorters, and lug chains. They can be used independently or in combination, depending on the type of container, the filling machine, and the product being placed in the container. The majority of all liquid filling machines operate as continuous filling devices. In most applications the machine has a large rotating filling head, which must be constantly supplied with containers. This is accomplished by a continuously running flat top chain conveyor feeding a star wheel or lead screw device. From here the containers are fed into the filling section. Star wheels when used alone separate the containers so they will be properly located beneath the filling stem. They can be made to handle a variety of container designs, although in some cases, the containers may have to be guided into the star wheel to ensure proper separation. Worm sorters are often used to guide containers into a star wheel. They can be short in length and only located near the machine in feed, or they may be full length of the machine&#;s main conveyor. The amount of container control determines the worm length. In most cases, worm sorters are very much like a wood screw; starting out small in diameter and then increasing to full diameter. A continuous pocket is formed at the root between the raised portion or crest of the thread. This pocket carries the container into its position on the filling machine by a rotating action. Because each container is different in design, worm sorters are usually made for individual applications and are not an &#;off-the-shelf&#; item. Lugged chains are normally used with inclined conveyors and semiautomatic filling machines. These machines can be either continuous or intermittent motion devices. The chain lugs are spaced to match the filling nozzles or stems. For example, if the filling stems are on four-inch centers. The chain is adjustable at the drive sprocket for timing purpose only. Position adjustments are usually made by moving the filling heads. Whatever method is used for container control, it is an important part of proper machine operation.
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