Packagers now are faced many challenges, especially on the cost of time and money. Thus, the involvement of machinery in streamlining the packaging process is a great need.
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Liquid filling machines are among the most sought equipment in the packaging business. And along with the rise of various beverages, there is an increase in production demands. This calls for more efficient ways of filling liquids in which liquid fillers take a great part in.
So in today&#;s topic, we are going to talk about the key elements you should know about liquid packaging machines.
What is a Liquid packaging Machine / Liquid Filler?
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A liquid packaging machine, also known as a flow filling machine, is used to fill products with different liquid viscosities into various container types either through the volumetric or quantitative filling. They can handle liquid products ranging from water-like to heavy-viscous and extremely thick ones.
No single type of liquid filler can simultaneously handle all kinds of liquids you see in different packaging industries. For example, a liquid filler that is made for packaging water might not be ideal for handling cosmetic products. Also, you cannot use a liquid filler meant for chemical products to fill dairy or pharmaceutical products.
Just like any packaging machine, liquid fillers are important in the manufacturing industry for promoting the efficiency and quality of the products being processed. Furthermore, the appropriate liquid filler machinery for your application depends on a variety of factors including the following:
The liquid viscosity, foam characteristic, and the size of the particulates present in your product
Chemical compatibility of your product and containers
The temperature in the packaging environment
Hazard considerations
Liquid Packaging Machine Trends
According to a report on automatic liquid filling market, the expected growth rate of the market for automated liquid filling machines from - is 7%. Meaning, the need for optimized packaging lines to increase production efficiency is increasing. An automatic filling machine helps meet this demand through the minimization of human errors because they are operated using computers.
Moreover, associated with the increasing demand for liquid fillers are the key trends in the market for liquid filling machines and the machines themselves.
Key Market Trends
Being amongst the basic necessities of life, the cosmetics industry is facing a lot of demands along with the rapid evolution of the market and increasing globalization. These demands include attractive packaging and automatic liquid packing equipment to drive sales and decrease the cost of human resources and money.
According to L&#;Oréal, the countries in the Asia-Pacific region, especially in China and India, have the highest demands for skincare products. There is also an increasing trend in online shopping and in consumers who are interested in physical appearance and personal hygiene.
Five Trends in Liquid Filling Machinery
Below are the five trends that packagers are following in liquid filling machines.
Shorter build times that meet the increasing demands of businesses.
Flexibility and adaptability to a wide variety of containers, closures, labels, and products.
Faster changeover of machine components to prevent holding stocks for retailers ordering at the last minute.
Compliance with the
Food Safety Modernization Act
.
Multi-functional machines (integrated machines that can handle multiple packaging operations such as filling, capping, labeling, and others).
How Does a Liquid packaging Machine Work?
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Every type of liquid filling machinery has its own operating mechanism. But in general, all liquid fillers incorporate similar working principles.
Regardless of how the machine handles the liquid product for the filling process depending on the liquid&#;s viscosity, all liquid fillers fill a specific amount of liquid into each container at a certain speed depending on the machine&#;s automation level. The number of filling nozzles the machine has will also affect how many containers it can fill simultaneously.
Fully Automatic Liquid Filling Machines
For fully-automatic liquid fillers, the containers travel through a power conveyor system to the filling station. The filling nozzles dispense the liquid product, which is contained in a cylinder or hopper, to the container either via quantitative or volumetric filling depending on the type of machine. We will discuss the various types of liquid fillers further in the next section.
Once the containers are filled, they continue traveling to the next stage of the packaging process which is usually the capping process.
Semi-Automatic Liquid Filling Machines
While fully automatic liquid fillers do not need much interaction with the operator, semi-automatic liquid fillers do not come with power conveyors. Thus, the operator will need to manually place the containers into the machine and then initiate the filling process via a finger or a footswitch.
Manual Liquid Filling Machines
There are also manual liquid fillers that are operated solely by hand. They are similar to semi-automatic filling machines but manual fillers do not require a power source for the filling process, unlike semi-automatic ones.
Types of Liquid Filling Machines
Liquid filling machines can be classified based on different factors. These factors include the machine&#;s usage/application and production speed as will be discussed in this section.
By Machine Orientation
Rotary Liquid Filler
The design of a specialized rotary liquid filling machine is typically much larger compared to inline liquid fillers. Rotary fillers can come in 25, 50, 100, or more filling heads. They are big and they fill containers at fast speeds, allowing your packaging line to produce far greater numbers of containers per minute compared to the capacity of an average inline filling machine.
But, when a complication occurs in the middle of the production process, many containers are wasted because many more containers are present in the filling machine in every given time. Thus, rotary liquid filler machines are more complicated to operate and fix compared to inline filling machines that allow operators to fix the problems on the fly.
With this being said, large thriving companies can benefit a lot from the unmatched speed and production capacity of rotary liquid fillers. This is why large enterprises such as Coca-Cola opt for these kinds of machines.
Inline Liquid Filler
As the name suggests, an inline liquid filling machine fills containers in a continuous line using a conveyor system. They are popular to packagers due to their cost-effectiveness and easy adjustment to each packager&#;s needs. They come in four to twenty filling heads/nozzles and sometimes more to accommodate the production requirements of different businesses.
Companies with low to medium production rate requirements often opt for inline liquid fillers. This is because the design of these machines allows for easier detection of problems during the production process.
When a complication occurs, you can easily stop, fix, and resume the machine into production at a faster speed compared to rotary liquid fillers. Thus, resulting in fewer numbers of wasted containers.
Some inline liquid fillers are designed to be scalable which allows packagers to increase the number of filling heads when their output requirement increases. This speeds up the production of your packaging line.
By Filling Principle
Vacuum Filler
Vacuum filling machines use vacuum feeding and vane cell feed systems. They are usually used for filling viscous/paste products. In the filling process, the liquid products are transported with the help of the following:
A vane cell feed system
A hopper integrated with a feeding device
The liquid products are drawn gently from the hopper into the vane cell feed system through the application of vacuum using a vacuum pump. This process happens once a pre-evacuated cell in the feed system moves underneath the hopper. This generates a continuous flow of the product during the filling process.
Volumetric Filler
Volumetric liquid filling machines fill products into containers via a volumetric filling principle. There are two common types of volumetric fillers: gravity and piston fillers.
Gravity Fillers
Gravity filling machines allow the operator to set the fill time of the individual nozzles of the machine. This allows the right volume of liquid product to be dispensed into each container for more accuracy.
In these kinds of machines, the liquid products flow through tubes towards the nozzles via gravity. This makes gravity fillers ideal for efficient filling of thin and free-flowing products versus thicker liquids that move slowly.
Piston Filler
Piston filling machines are more suitable for thicker and high-viscosity liquid products but they can handle thin liquids too. Thick products do not flow freely so they need a little help before they can reach the bottles. You can also use these machines for products containing large particulates such as bits and pieces of fruits and vegetables
Piston fillers fill products into a cylinder first before using pistons in pushing the product from the cylinder towards the waiting containers below the filling nozzles. The unchanging volume of the cylinder helps in achieving accurate volumetric fills.
Overflow Filler
Overflow filling machines adopt the principle of overflow filling as indicated by their name. These machines provide an alternative to the volumetric fill of gravity filling machines.
Instead of filling a certain amount of product into each bottle, overflow fillers fill each bottle with identical levels of liquid, regardless of the bottles&#; slight volume differences. Thus, making overflow fillers an ideal solution for filling clear containers. This is because these machines give an aesthetic value to the products once on the shelves.
Moreover, overflow fillers work best with thin liquid products and for foaming products that need to be controlled during the process of filling.
Pump Filler
Pump filling machines are perfect for handling thick products. They can match the pump to your liquid product for more efficient and consistent fills made possible by the different kinds of pumps you can choose from.
Packagers have the option for either pulse or time based fills when using pump fillers. These machines add a little push in getting thicker liquid products such as oils, gels, and others. But, there are also pumps that are suitable for low-viscosity products as well.
Net Weight Filler
Net weight filling machines work by filling containers using a fixed weight set by the operator. They use weighing scale platforms in monitoring product weights as the product is being filled into a container. These machines are ideal for filling bulk quantities of liquids into containers with very high values, like 5-gallon pails, that you need to weight correctly to prevent profit loss.
Moreover, net weight filler machines are suitable for fills that are highly accurate, especially when packaging products that are labeled by weight.
By Operation/Automation
Automatic Liquid Filling Machine
Fully automatic liquid fillers will not require much human interaction because the whole filling process is automated. This dramatically increases the filling rate of your production line.
These machines come in full portable frames which allow the packager to install a power conveyor system for automatic filling of the containers. Businesses having high-production demands and large-scale operations are the ones who use automatic liquid filling machines.
Features of Automatic Liquid Filling Machines
They have conveyor systems with variable speeds to give more flexibility to the packager.
Automatic liquid packaging systems can package liquids in all viscosity levels and even the ones that contain food products.
They are integrated with PLC control systems which allow packagers to configure the machine based on their container type and their desired volume per container.
You can add more filling heads to these machines to increase your filling line&#;s production rate.
Automatic liquid fillers can fill 5-milliliter to 10-liter containers with production speeds of up to 120 containers per minute.
Semi-automatic Liquid Filling Machine
As mentioned earlier, semi-automatic liquid fillers require the operator to manually place each container below the filling nozzle and start the filling process via a switch.
Once the containers are filled, the operator needs to remove them by hand then transfer them to the succeeding stage of the packaging process. Moreover, some semi-automatic fillers might require the operator to refill the products as necessary.
Tabletop liquid fillers are the commonly used types of semi-automatic fillers. They come in designs that provide the operator enough room to move each container to and from the machine in each filling cycle.
Features of Semi-Automatic Liquid Filling Machines
Though these machines are faster compared to manual liquid fillers, their production speed will still depend on the operator&#;s speed, unlike fully automatic liquid fillers that can achieve a consistent speed via power conveyors.
Semi-automatic liquid equipment are ideal for small to medium production requirements and seasonal high-volume productions.
They are usually designed with nozzle, piston, and syringe components for maintaining a zero-drip filling process.
Some models of semi-automatic liquid fillers are designed with production speeds reaching up to 800 containers per hour in filling 5-milliliter to 1,000-milliliter containers.
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Manual Liquid Filling Machine
As the name states, a manual liquid filler is manually operated and does not require a power source or electricity. This makes them suitable to be used in applications where electricity and compressed air are not available.
Features of Manual Liquid Filling Machines
Manual liquid fillers are ideal for packaging different types of liquids along with medium-viscosity products such as gels, shampoos, and creams.
These machines are recommended for laboratories or any small scale production applications.
They provide increased output speed and accuracy compared to filling by hand.
Manual fillers can fill vials and bottles of up to 600 milliliters depending on their model within a production speed range of 15 to 900 containers per hour.
By Liquid Type
As mentioned earlier, the viscosity of your liquid products will have an impact on which filling principle is the most appropriate one for your application. Some liquid filler types are more appropriate in filling free-flowing liquids and some are also better at handling highly viscous products.
Below are the recommended liquid fillers to use for each type of liquid viscosity based on the filling principle the machines adapt.
Free-Flowing Liquid
Free-flowing liquids are thin, water-like, and have low viscosity values. Thus, overflow and gravity filling machines are more appropriate for these types of products.
Viscous liquid
Viscous liquid filling machines are used for handling thick liquid products with high viscosities. These machines include pump and piston filling machines. Vacuum liquid fillers are also recommended for paste products.
By Container Type
Lastly, aside from the aforementioned categorizations, liquid fillers can also be classified further according to the type of container that the machine is handling. Different filling machines are used to handle different types of packages such as the following:
Can / Tin, Bottle, Pouc, Bag-in-boxes, Bags, Jars, Pots, Vials, Bottles, Tanks, Buckets, Sacks, Pails, Ampoules, Canister, Drum, Tray, Jug
Applications
With the flexibility of modern liquid filling machines, you can pretty much fill any type of liquid product using them. But do note that some adjustments would be needed on your desired machine for handling different liquid products such as the ones listed below per industry.
#1 Food and Beverage
Water, Ice Cream, Cordials, Lassis, Fruit Juice, Smoothies, Yoghurt, Syrups, Honey, Wines, Liquors, Spirits, Soft Drinks, Alcohol, Vinegar, Oils, Mayonnaise, Dips and Dressings, Sauces, Salsa, Mustard, Marmalade, Jam, Ketchup, etc.
#2 Healthcare and Pharmaceutical
Vitamins, Minerals, Vitamin Supplements, Food Supplements, Cough Syrups, Cold and Flu Remedies, Paracetamol Suspensions, Digestive Remedies, Sports Nutrition, Anesthetics, Solvents, Eczema Creams, Acne Treatments, Lotions, Sun Creams, Skin Care Products, Foot Care Products, Ear Drops, Eye Drops, Lubricants, etc.
#3 Cosmetics & Toiletries
Foundation, Make-Up Remover, Face Cream, Nail Polish, Nail Polish Remover, Lotion, Face Masks, Depilatory Wax, Hair Dye, Hair Wax, Hair Gel, Shampoo, Conditioner, Liquid Soaps, Bath and Shower Gels, Deodorants, Toothpastes, Perfumes, Body Sprays, Massage Oils, etc.
#4 Chemicals
Paints, Printing Inks, Coatings, Glues, Construction Sealants, Bonding Solutions, Rust Treatments, Surface Coatings, Cutting Fluids, Thread Locks, Release Agents, Isopropanol, Acetones, Methanol, Thinners, Bleach, Detergents, Deodorisers, Disinfectants, Degreasers, Descalers, Polishes, etc.
#5 Veterinary Products
Deodorants, Shampoos, Conditioner, Flea and Tick Treatments, Stain and Odor Remover Products, Isotonic Drinks, Vitamins and Minerals, Nutritional Supplements, Disinfectants, Iodine, Sheep Dip, Udder Treatments, Insecticides and Repellents, Ear Cleaners, Eye Drops, Oral Suspensions, Aqueous Creams, Liquid Anaesthetics, Lotions, etc.
#6 Automotive
Lube Oils, Coolants, Antifreeze, Screen Washes, Degreasers, Shampoos, Polishes, Air Fresheners, Leather Care, Paints, Wax Oils, Chain Lubes, Visor Cleaners, Cleaners, Puncture Repair Products, Hydraulic Fluids, Paints, Varnishes, Anti-Fouling Liquids, Upholstery Cleaners. etc.
#7 Home & Gardening
Fabric Softeners, Disinfectants, Bleaches, Window Cleaners, Toilet Cleaners, Floor Cleaners, Paints, Varnishes, Wood Stains, Sugar Soaps, White Spirit, Brush Cleaners, Paint Strippers, Adhesives, Fertilizers, Insecticides, Herbicides, Weed Killers, Fragrances, Diffusers, Air Fresheners, Deodorisers, Aromatherapies, Essential Oils, Leather Cleaners, Leather Dyes, Fabric Protectors, Shoe Polishes, Shoe Cleaners, etc.
Tips for Selecting a Liquid Filling Machine
For newbie packagers, the process of selecting a liquid filling machine for their project can be an overwhelming process. How will you know that you are choosing the right one for your specific application? Of course, your choice of machine is going to depend on a lot of factors.
So to help you a bit on how to choose the appropriate liquid filling machine for your business, below are some important tips that we have compiled for you.
#1 Be specific on the type of liquid you are filling.
Before purchasing a liquid filling machine, the very first question that you should ask yourself is what liquid products will you be handling. Different filling equipment handles different liquid viscosities &#; from free-flowing to highly viscous ones. Thus, it is important to consider your liquid product&#;s consistency and viscosity when buying a liquid filler.
#2 Consider your liquid product&#;s unique characteristics.
There are liquid products with changing viscosity values when subjected to temperature change. Meanwhile, other liquids might include particulates. Examples would be salad dressings and liquid soaps. Any of your product&#;s unique characteristics will affect which type of liquid filling machinery best suits your project.
#3 Consider what type of containers you will be using.
As mentioned earlier, different liquid filling machines will be used for handling different types of containers. For instance, overflow filling machines are more suitable for clear containers. These machines fill at consistent levels without any regard to the slight inconsistencies in the interior volume of the containers. Thus, providing your products a pleasing appearance upon reaching the shelves.
#4 Know your production requirements.
Your desired production requirements will determine the ideal automation level for your liquid filling machine. Different machine automation will have their own production capacities so you will have to know your production demands.
Conclusion
Searching for the appropriate liquid filling machine for your application can be a long process. But, being knowledgeable about the key elements associated with these machines can help you a lot.
For better results, it is recommended that you choose a good liquid filling machine manufacturer who can help you in the selection process. Moreover, there will be times wherein a few modifications on the existing liquid fillers would be needed to better accommodate your packaging line&#;s needs. Thus, machine customization is also important when searching for a manufacturer.
Levapack offers both machine customization and consultation services prior to the manufacture of your ideal liquid filling machine. So feel free to check out our products and contact us for a perfect packaging solution!
Reference: https://www.fda.gov
When it comes to choosing a supplier for your packaging materials and machinery, it is important to do your homework and ask yourself a few questions. You should investigate at least three different suppliers and learn about several important dynamics from each of them.
It is a good idea to choose a packaging machinery supplier who is relatively close to your geographical location or can easily travel to you. This will have an impact on your business when there is a need for repairs or emergency service for your equipment. Pick a supplier who is in another country and you may find yourself dead in the water for days on end. Choosing a supplier with technicians who are local is always a smart idea. When it comes to your materials, you don't have to be as worried about the physical location as most supplies can be shipped timely.
It is important to choose a packaging machine supplier with experienced and certified technicians who are professionally trained to work on your packaging equipment. Without the proper certifications, you are taking a chance with your equipment. You could end up paying big when risking service with non-certified techs.
It may be tempting to source the cheapest packaging materials in an attempt to save money, but if you buy from a company with poor customer service, you may end up losing the anticipated savings anyway. Poor service often means lost dollars. Check out reviews of each vendor and if possible, reach out to current customers and ask about their vendor's customer service and if they would recommend buying from them.
There is an old saying in the packaging industry and that is "shrink film is shrink film". While there are some brands with flashy marketing and sales gimmicks with a premium price, chances are, there are several less costly alternatives that are of equal quality. If you are looking for comparisons, there are generally low-cost films that have lower clarity and higher-cost films that will shine more and have better clarity. Choosing an inexpensive film may cost you in shelf presence.
Snake oil and elevator pitches can blur the line between reality and illusion. At the end of the day, you will want to purchase from an honest supplier who carries multiple offerings at different price points and provides superior customer service.
Depending on how often your machinery is running, your downtime due to repair needs or emergency service will vary. As time is money, it is important to ask your machine supplier about lead times, parts availability, and preventative maintenance programs.
Ask each potential vendor what their average response times for emergency calls are. In most cases, it should not be more than 24-48 hours.
Different types of machinery require different types of materials and utilize different amounts of materials based on the make and model of equipment. For example, while you can save money upfront by purchasing a manual L-Bar Sealer, your cost of goods will likely be higher as a more expensive automatic sealer will generally use less material than the manual machine because the machine will generally be optimized to do so.
That being said, the quantity of product that you will be producing must also be taken into consideration. An automatic sealer won't be the right machine for a small business that is only running a couple of thousand items or less each week.
This is due to the fact that each model is designed to work with specific maximum and minimum capabilities and materials. Every machine is different. Your packaging line's unique needs must be taken into consideration when choosing the appropriate machine for your application. This can result in higher production costs if your choice of machinery cannot run thinner gauge shrink film. Using thinner gauges of shrink film can result in significant cost savings.
Buying packaging machinery is a major investment. The various dynamics of choosing machinery include; safety, budget, physical layout, electrical supply, materials, and a whole host of considerations that can make your head spin.
When moving forward with the buying process it is important to start by reviewing the appropriate KPIs with an emphasis on safety first. Next, you will want to be sure to complete the packaging machinery pre-investment checklist. After filling out the information in this valuable tool and getting your results back, you will want to move on to getting quotes from at least two or three vendors.
Getting an analysis of your packaging department and collecting data on your current machinery, manual labor, materials, physical footprint, electrical requirements, production levels, types of products and the other important dynamics of running a safe and productive packaging line is key.
Once you have been able to fully analyze every aspect of your packaging line, asking for quotes from each of the vendors you are giving an opportunity to quote will provide you with peace of mind that you are going get the best deal and receive the best of what each vendor has to offer.
In addition to requesting information and pricing on the packaging machinery you are looking to purchase, be sure to also acquire information about the cost of service, installation, any training available, supply, and repairs. Ideally, you should consider getting a quote for a long-term preventative maintenance plan as this type of program will ensure that your machinery is always running at peak performance and that downtime will be limited when it does occur.
Once you have chosen a vendor to buy from, meeting with your representative and reviewing the machinery offerings that they have will allow you to open a conversation about pricing. Here you can ask about special offers, rebates, additional options, leasing versus buying, and other related dynamics that will help you to get the best price and best plan implemented for your specific budgetary restraints and packaging line needs.
Finally, it would do you well to schedule quarterly, bi-annual or annual meetings for review with your chosen vendor's sales representative and one of their maintenance technicians.
This will allow you to review data from one meeting to the next and identify places where your machinery and materials could be improved upon to further reduce your cost of production, increase speed to market, create greater efficiency and produce a superior performance on your packaging lines KPIs.
Once you have purchased your new machinery and have worked with your chosen vendor to install the machinery, train your operators, and all else has been said and done, be sure to schedule your first review before your representative leaves your building.
If you heed the information in this guide, we assure you that you will make the best possible choice of packaging machinery for your packaging department. Furthermore, you will be able to ensure the purchase and implementation of the best materials for your products and may rest assured that you have done everything in your power to have the best possible packaging line for your business.
Should we not have produced answers to some of your questions or content that is crucial to your particular needs in regard to buying new machinery, contact us directly. Your voice can help others in your position in the future!
Our dedicated packaging professionals can and will answer any questions that have not been answered by this guide. In addition to what you have read here, we invite you to peruse our blog which is absolutely packed to the brim with useful information, free tools, and quality content that will make for a highly useful adjunct to this guide.
Last but not least, you will find a selection of free tools below that will help you on your journey to finding the best packaging machinery for your packaging line.
From all of us here at Industrial Packaging, we wish you well on your quest and again would implore you to contact us if you need anything else that you could not find in this guide.
Are you interested in learning more about automatic liquid packaging machine? Contact us today to secure an expert consultation!