Choosing the Right Filling Machine

A filling machine, or filler, is a packaging machine that ensures uniform filling of a container with various products. This type of machine is used in a wide range of sectors, including the food, cosmetics, and pharmaceutical industries, and for a large variety of packaged products.

View our filling machines

  • How to choose a filling machine

    Selection criteria for a filling machine:

    Product to be packaged: This refers to the nature of the product. Is it a liquid, viscous, foamy, pasty, gaseous, or solid product? Is it a sticky product? Note that carbonated beverages, like champagne, require special pressurized filling and capping machines that eliminate air from the bottle.

    Type of container: One of the critical factors to consider when purchasing a filling machine is the type of container you will be filling, its material, shape, and size. Do you need bottle fillers, bag fillers, container fillers, can fillers, drum fillers, etc.? The material of the container is also crucial. Are you using bottles made of glass or plastic, or Tetrak Pak cartons? If your container has a cap, we recommend opting for a filling and capping machine. The shape and size of the container will also impact the options available for your filling machine. It’s best to choose a machine that offers great flexibility and can handle a wide range of container shapes and sizes.

    Production speed: This will depend on your production needs and the size of your business. Small filling machines have production rates expressed in the number of containers filled per hour, while large filling machines have rates indicated in the number of containers filled per minute. For large-scale productions, opt for large filling machines.

    Operating mode: This refers to the machine’s level of automation. Fillers can be manual, semi-automatic, or automatic.

    Available space: Filling machines can be quite bulky, so you must ensure you have enough space in your workspace.

    Maintenance: If you use your filling machine to package different liquids, you will need to clean it each time you change liquids. However, cleaning a filling machine often requires disassembling all of the parts that come in contact with the product. You can always opt for an electric filler with an integrated cleaning system that cleans the machine without the need for disassembly.

  • What level of automation should you choose for your filling machine?

    Cozzoli Machine Company automatic filler

    Cozzoli Machine Company automatic filler

    Automatic Fillers

    These are fully automated and do not require an operator to run. Containers are sent by a motorized conveyor to the filling station, where filling nozzles dispense the product. Once filled, the containers are sent to the capping and packaging station.

    These filling machines have several advantages:

    • They increase packaging speed, which reduces process time.
    • They are integrated with PLC control systems that allow adjustability based on container type and the desired quantity per container.
    • They offer a good working speed.
    • They provide precise dosing.

    The main drawback of these machines is their price, which is very expensive. They are recommended for work in the chemical and pharmaceutical industries where production volumes are high.

    Semi-Automatic Fillers

    All-Fill semi-automatic filler

    All-Fill semi-automatic filler

    Like automatic fillers, these can package any type of product in containers made of plastic, glass, stainless steel, etc. 

    They are called semi-automatic because some tasks are performed manually. They are not equipped with electric conveyors, therefore, the operator is required to manually place the containers and start filling them by pressing a button or pedal. They are, however, equipped with an electric power source for the filling process.

    Their advantage is that they offer a good working speed at a more reasonable price than fully automatic filling machines.

    Manual filling machines

    COVEN EGIDIO manual volumetric filler

    COVEN EGIDIO manual volumetric filler

    These operate solely through the action of the operator who actively participates in the filling process. The operator starts and stops the machine and weighs the quantities. The filling process is manual compared to the semi-automatic machine, which offers an electric filling process.

    These machines are less expensive but do not offer a high throughput. Manual fillers are recommended for small-scale productions, such as in laboratories.

  • Inline vs. rotary fillers

    Inline filling machines

    Automatic inline filler from Shemesh Automation Ltd

    Automatic inline filler from Shemesh Automation Ltd

    As their name suggests, inline fillers fill containers in a linear manner. They are smaller than rotary fillers, fully automated, and capable of filling up to 200 containers per minute.

    They are very cost-effective, easy to maintain, and easily adjustable. They adapt to a wide variety of containers and can be easily stopped if there is any issue in production.

    They are ideal for small and medium-sized businesses.

    Rotary filling machines

    PACK'R automatic rotary filler

    PACK’R automatic rotary filler

    These machines are much larger than inline machines and can fill containers at very high speeds, up to 300 containers per minute. This enables your packaging line to fill many more containers per minute than it can with an inline filling machine.

    It is possible to choose the number of filling nozzles in order to adjust the production speed.

  • What are the different filler models?

    Filling machines are mainly either volumetric or net weight fillers.

    STOPPIL automatic volumetric filler

    STOPPIL automatic volumetric filler

    Volumetric filling machines

    This type of machine uses volumetric dosing, which relies on a pump. The pump draws in a volume of product stored in a tank and injects it into the container to be filled.

    Several pumps can be used for volumetric filling, including piston pumps. 

    Tenco piston filling machine

    Tenco piston filling machine

    Piston fillers are suitable for thicker, pasty, high-viscosity products such as jams and jellies that flow more slowly. Piston fillers start by feeding the product into a cylinder, then a piston pushes the product from the cylinder into the container waiting under the filling nozzle. The volume of the cylinder is constant and corresponds to the dosing capacity. This enables precise volumetric filling.

    These machines are also suitable for working with liquids.

    Other types of pumps commonly used in industrial filling include peristaltic pumps and gear pumps.

    All-Fill automatic net weight filler

    All-Fill automatic net weight filler

    Net weight filling machines

    Net weight fillers, also known as gravimetric fillers, weigh the dosed product using a load cell or balance, which can be used to cut off or activate the pump flow and even modulate its output. Net weight fillers are compatible with all types of products, whether liquid, pasty, or viscous, and at temperatures ranging from 10°C to 100°C.

    They are mainly used in the cosmetics, food, and chemical industries.

1 Star2 Stars3 Stars4 Stars5 Stars (No Ratings Yet)
No comment

Leave a Reply

Your email address will not be published. Required fields are marked *