Filling Machines and How They Work

Filling bottles can seem like a fairly simple process, just get the liquid into the containers. However, each type of filling machine manufactured by Liquid Packaging Solutions gets the liquid into the bottle using a different principle, such as filling to a level or to an accurate volume. It is this accuracy, combined with greater efficiency, that makes bottle fillers an integral part of a packaging system.

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Gravity Filling Machines

Gravity fillers allow packagers to get an accurate volumetric fill by placing a tank above the fill heads. As you might imagine, gravity plays a large part in completing the fill. With the raised tank, valves can be opened and closed for a pre-set amount of time to allow product to flow from the tank into the waiting bottles. When that pre-set time elapses, the valves will close cutting off the flow of the product. The time for each fill head can be set individually to allow for accurate volumetric fills on multiple head machines. Given that gravity is the main mover of product with these liquid fillers, the gravity filler is best suited to free-flowing products, as thicker, slower moving liquids would not allow for an efficient fill.

Pump Filling Machines

Pump filling machines also allow for an accurate volumetric fill but add a little boost to the movement of the liquid. Unlike gravity fillers, pump filling machines will use a single pump for each fill head to move product through the pathway and into the bottles. Pump fillers allow packagers to fill by time, like a gravity filler, or by pulse. Pulse fills correspond to a specific movement of the pump or pump components. For instance, for a gear pump a pulse may be equal to a half turn of the gear. The pumps allow thicker products to be efficiently moved where gravity alone may not suffice, and either the timed fill or the pulse will provide an accurate volumetric fill.

Piston Filling Machines

Finally, piston filling machines also allow for a volumetric fill, but in a slightly different manner than the filling machines described above. With this liquid filler the piston moves in and out of the cylinder. As the piston retracts, product is pulled into the cylinder. The piston then returns to the cylinder to push product out and into waiting containers. As the volume of the cylinder never changes, the piston filler provides an accurate volumetric fill. Like the pump filler, the piston also provides an extra push to help move product, and the open space of the cylinder makes this machine ideal for highly viscous products as well as product with particulates, like jams with fruit pieces.

Overflow Filling Machines

Rather than fill to a specific volume, overflow fillers fill each bottle to the same level, even if volume will vary slightly. This bottle filler uses a special nozzle that dives onto the container and creates a seal over the bottle opening. Product is then released and continues to flow until it reaches the desired level. Once that level is reached, the liquid returns to the holding tank via an overflow opening in the nozzle itself. Once product stops flowing the nozzles rise from the container creating a level fill. These machines are ideal for those packaging in a clear container where a product line on the shelf is obvious. While the overflow filler does use a pump to move product, it is also better suited to low or medium viscosity products as thicker products would take an excessive amount of time to fill and could clog the product pathway or return port to make achieving level fills difficult or time consuming.

While most packagers will either fill by volume or to a level, there do exist other principles for different products, including a net weight fill. To learn more about all of the different principles, or for assistance in finding the right principle for your own products, call LPS and speak with a Packaging Specialist today.

The automatic filler has found an irreplaceable spot in the food packing and cosmetics industry. In fact, the revolutionary piston filler will likely have a compound annual growth rate (CAGR) of 4.1% in the - period. 

The piston filler market has seen a significant revenue bump since end-use industries decided to invest in it to eliminate possible product contaminations.

So, what&#;s the key to its success, other than the fact that it increases productivity and efficiency while reducing manufacturing and workforce costs? Let&#;s discover how a piston filler works. 

What&#;s a Piston Filler Good For? 

Piston filling machines, or piston fillers, are extensively employed for packaging thick and viscous liquids. They are also ideal for products, particularly food items, which deteriorate if not packed suitably. In essence, a piston filler swiftly transfers the product material into its intended container with high precision.

Mainly used in the food industry for packing pre-prepared meals, sauces, pastes, and oily ingredients, piston fillers also claim their space in the cosmetics sector, handling shampoos, conditioners, heavy oils, wax cleaners, gels, and creams effectively. 

The best selling points of a quality piston filler are that you can avoid spills and leaks and reduce labor costs, all the while increasing volumetric accuracy.

The Build of a Piston Filler 

Before understanding how a piston filler works, let&#;s check out its main components:

• Hopper

  &#; This large canister holds the bulk of the unpacked product.

• Piston

  &#; It suctions the product from the hopper and transfers it to the piston cylinder.

• Piston Cylinder

  &#; This part undergoes continuous suction and compression cycles, ensuring consistent filling.

• Valve

  &#; An essential component that regulates the flow of the product, preventing unnecessary leaks.

• Nozzles

  &#; They control the amount of product dispensed and direct it into the containers.

By working in harmony, these components form the backbone of a well-functioning piston filling machine, enabling efficient and precise product packaging.

How Do Piston Fillers Work? 

Since we&#;re now familiar with the primary parts of a piston filler, here&#;s how it works in practice:

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Part I: Getting the Product Material Out of the Hopper

Understanding how piston fillers work begins with the hopper. When the valve opens, the released product leaks from the hopper to the cylinder due to open airflow. The piston, which is preset to pull the packing product amount, arranges the product doses, creating equal doses for the packing container. 

Part II: Getting the Product Material Into the Container

When the valve starts rotating, it closes a portion of the hopper, allowing the right amount of liquid product to come out through the nozzles. The piston assists with applying pressure for the product to easily move through the nozzles into the container, allowing for packaging more empty containers at once. 

This aspect is the main feature benefiting the business: increased production at a lower cost in a faster time frame compared to manual packing. 

Expanding on How Piston Fillers Work

Precision in Dosage

One of the hallmarks of a piston filling machine is its precise dosage control. Unlike manual packing methods, where inconsistency is common, piston fillers ensure uniformity that not only conserves resources but also maintains product integrity. The consistent pressure and flow managed by the piston and valve system reduce wastage, ensuring each container is filled accurately.

Versatility in Application

Piston fillers are versatile, adapting seamlessly to various product viscosities and container sizes. This adaptability makes them suitable for a wide range of industries beyond food and cosmetics, including pharmaceuticals and chemicals, where precise filling is critical. The capability to handle both thick and thin liquids demonstrates the robustness of piston filling machines.

Ease of Maintenance

Regular maintenance of a piston filler is straightforward due to its relatively simple mechanical design. Easy access to components means that routine checks and cleaning are quick, minimizing downtime. Properly maintained piston fillers can offer years of reliable service, representing an excellent return on investment.

Piston Fillers in Action

Food Industry

In the food industry, companies using piston fillers can see substantial improvements in their operations. For instance, sauce and paste manufacturers can experience a reduction in product wastage and labor costs after integrating piston filling machines into their production lines. Moreover, the precision of these machines ensures that each package meets quality standards, reducing the likelihood of customer complaints.

Cosmetics Industry

Cosmetics companies, on the other hand, benefit from the ability of piston fillers to handle high-viscosity products like creams and gels. Skincare brands can potentially observe an increase in their output, thanks to the efficient and precise filling capabilities of piston filling machines.

Volumetric Technologies: Buying Quality at a Reasonable Price

When searching for a high-quality piston filling machine, look no further than Volumetric Technologies. Our piston fillers are engineered with meticulous attention to encompass durability, efficiency, and precision.

Do you need an immediate solution for product packing with on-site-installation? Volumetric Technologies offers robust solutions tailored to meet your industry needs. Our piston fillers guarantee a cost-effective, leak-free, and spill-free operation, ideal for food, beverage, cleaning supplies, and cosmetics industries.

Why Choose Volumetric Technologies?

Quality Manufacturing

We pride ourselves on manufacturing piston filling machines that stand the test of time. Our commitment to quality ensures that each component meets rigorous performance standards, delivering reliable performance for years to come.

Customer Support

At Volumetric Technologies, customer satisfaction is our top priority. Our team is dedicated to providing unparalleled support, from consultation to installation and beyond. We offer free consultations to help you choose the best piston filling machinery for your specific needs and ensure seamless integration into your existing production lines.

Industry Expertise

With years of experience in the industry, our expertise allows us to offer insightful guidance and innovative solutions. Our piston fillers are designed not just to meet but to exceed your expectations in various applications.

Where to Find the Best Piston Filling Machines

Piston filling machines represent a blend of efficiency, accuracy, and versatility, making them indispensable in many packing industries. From ensuring precise dosage to adapting to different product viscosities, piston fillers streamline the packaging process. 

Investing in a quality piston filler from a trusted provider like Volumetric Technologies can significantly enhance your production efficiency, reduce costs, and maintain high-quality standards. Our piston fillers are made with care and attention to detail; simply let the machine do its thing without worrying about possible leaks and spills!

Need an extra hand in the food and beverage, cleaning supply, or cosmetics industry? Contact our team and request a free consultation today! We look forward to partnering with you to achieve excellence in your packing processes.

For more information, please visit Paste Thick Liquid Filling Machines.