Importance of Liquid Filling and Capping Machine
Multifunctional Filling or Capping Machines are widely used in the pharmaceutical & FMCG industry because of their efficiency and consistent results. The Semi-automatic Volumetric Liquid Bottle Filling Machine works on the basic principle of volumetric with syringe & piston & nozzle. It is widely used to fill liquid in containers like bottles in food, agrochemical, beverages, and pharmacy industries.
The digital liquid filling machine uses the syringe to fill the liquid, it is very compact and it can multifunction to meet the custom requirement of mass filling of the containers. The machine consists of its pumping system to fill the assigned volume in the container. The liquid flow is measured and converted into electrical signals which are controlled by the PLC base circuit. The machine can be programmed to fill different volumes in different size containers. It uses a gear pump set to meter the filling device to correctly fill the gel or liquid amount.
Bottle Filling machine or fillers are used to fill bottles in not only food industries but other industries also like shampoo, powders, tablets, and conditioners due to their benefits like decrease in manual labour hence reducing operation cost, reduce in set up time, easy to operate by some buttons, easily washable, durability and longer operation hours & life, cost-effective packaging. These machines can easily work on wide products with different viscosities and container volumes.
Oral liquid Manufacturing system involves a closed circuit manufacturing facility from supplying sugar/water phase to loading of volumetric flavor drink filling machine. The plant helps in ensuring hygiene with no human touch anywhere up to the Filling machine hopper. It shafts operate vibration-free along with no coupling in the drive assembly. The storage vessel also consists of stirrer for suspension in a closed vessel.
Capping and sealer machines
Capping machines are extensively used in liquid good manufacturing industries in pharmaceutical and FMCG industries to apply cap or lid to every container securely in the packaging process. The aseptic filling machine helps you to speed up the manufacturing process with sanitization and quality. The bottle capper machine not only places a cap on the container but also sorts them, elevates them, and finally seal them acting as cap sealer machine. The machines are extremely flexible and can fit into the desired workplace effortlessly.
For the flip-off cap or tear off cap a capping machine known as vial capping machine, it is used to seal Glass Vial or bottle. Vial capper is an imperative product in the injectable formulation plant as it assures an ideal hermetic seal to ensure the integrity of medicine inside the glass bottle. The quality vial capping is helpful for paramedical staff during the injection process by smooth removal and quality assurance. It also protects the stopper from any outer damage by firmly holding a stopper in the sealed position and maintaining sterility of drug. All these machines form an important part of pharmaceuticals and FMCG companies to continue their production safely and efficiently.
Increasingly, manufacturers are recognizing the advantages of transporting dry bulk ingredients in flexible intermediate bulk containers (FIBCs or bulk bags). The savings in ingredient costs, material handling, warehousing and transportation requirements can be substantial.
These benefits can only be realized when appropriate bulk bag filling equipment is applied. Properly designed FIBC bulk bag fillers deliver a dense, stable package that can be safely and easily stored, transported and discharged. The savings that properly filled FIBCs deliver can be augmented by automating the filling system to increase filled bag output.
Depending on the application, automated bulk bag filling systems can range from a single, microprocessor-controlled machine filling 10 bulk bags per hr, to multiple units each outputting 20 bags per hr, to a single, multistation filler production 70 one-ton bags per hr.
Any benefits from filling FIBCs in greater volume must be qualified by careful analysis of the quality of the resulting filled bag. For example, if you use one filling machine to fill 20bags per hr without proper densification, but then have to store them unstacked or in racks because the bags are leaning and unstable, you are paying a premium for storage space, transportation and labor.
It is most effective to specify a expansion bag filling machine that maximizes the ingredient in the bag and produces a straight and stable package. Then, once you can stack, convey and transport the filled bag efficiently, you can investigate automation techniques to best match your production rates and secure the highest efficiency for your operation. Look for a bulk bag filler designed to hang fill the bag to produce straight sides and to fill the corners of the bag first to maximize stability. A fill should also densify and compact the ingredient and weigh the bulk bag accurately and reliably.
Bulk Bag Filler Automation Opportunities
Filling a bulk bag comprises three main operational steps: rigging the bag, filling the bag and taking the filled bag away from the machine. Automation of an FIBC filling machine can be approached on four levels: 1) adding an automatic control system to a manual machine, 2) automating the removal of the filled bag and placing of the pallet (if necessary), 3) preweighing the ingredient to reduce overhead time associated with bag rigging and ingredient feeding, and 4) providing a multistation machine to simultaneously perform the three operational steps.
A typical filling operation requires the rigged bag or liner to be inflated, the weight of the machine or part of the machine to be tared out, the fill to be initiated, the densification and compaction to be cycled, and the fill rate to be slowed by some method in order to successfully achieve the target weight.
A microprocessor-based controller can automate almost all of these steps. Once the operator has rigged the bag and inflated it, taring the weighing system initiates the automated fill cycle, whereby the controller takes over the sequencing of starting and stopping ingredient flow into the bag, densification and weighting. A typical bulk bag filling system of this sort can achieve an output of up to 10 bags per hr depending on the maximum flowrate of ingredient into the bag. A manual system may be only capable of six to eight bags per hr.
Automatic Bulk Bag Removal
Typically the filled bulk bag is removed from the filling machine by a forklift truck. Providing a means of quickly freeing up the space inside the filling machine to rig a second bag, once the first is full, can increase the output rate and reduce the need for a dedicated forklift truck. Roller or chain conveyors can be positioned in the filler to remove the filled bag automatically. Conveyors, either motorized or gravity type, can be added to allow filled bag accumulation for later transport by forklift truck.
Pallet and slip sheet dispensers can be added to the system, along with additional motorized conveyors, to automatically position a pallet in the machine or to pick up the filled bag on a pallet. This eliminates the need for an operator to manually place the pallet in the machine.
Automatic bulk bag removal can increase the output of a stand-alone, microprocessor-controlled filler to 12 to 14 bags per hr. Filled bags with specially designed lifting loops can be handled easily with fork trucks. This may further increase system output as pallet need not be accommodated.
Preweighing Bulk Bags
The final step to increase the output of a single station filler is to reduce the time required to feed ingredient into the bag to meet a target weight. This can be done by preweighing the ingredient in a weigh hopper located directly above the filler. The “charge” of ingredient is fed into the hopper to the target weight while the system or operator removes the previously filled bag and rigs the next.
Once the new bag is rigged, the preweighed charge is dropped into the bag quickly. As soon as the charge has left the preweigh hopper the system begins to fill the next bag’s charge in the weigh hopper. In this configuration, the bulk bag filling machine itself does not perform weighing and, therefore, does not require a weighing system. However, the overall control system must be expanded to simultaneously perform weighing in the preweigh hopper while controlling the other functions associated with densification, automatic bag removal and pallet and slip sheet dispensing. Pre-weighing, in association with automated controls and automatic bag removal, can increase the output of a single filling station to 20 bags per hr.
Multiple Bulk Bag Fillers Increase Bulk Bagging Rate
For production rates greater than 20 bags per hr, multiple bulk bag fillers can be used. The capital cost versus production rate must be assessed to arrive at the most effective total system configuration. For example, if 30 bags per hr are required, two automatic bag removal systems would be most appropriate. If 40 bags per hr are required, two preweighed, automatic bag removal systems would be selected.
More bulk bag filling machines can be added and sequenced to further increase bag output. If more than 50 bags per hr are required a decision must be made based on available space, operator availability and associated labor costs and capital cost. A high-capacity system may be justified in this case.
If more than six bulk bags per hr are needed to be filled, it is worth considering automation possibilities. A single machine’s output can be enhanced by filling-specific controls of the doypack filling and capping machine, preweighing, and integrating conveyors and pallet and slip sheet dispensers. Further, increases in output can be achieved by applying multiple units as long as sequencing of the operator functions is carefully reviewed.
There is an ever-increasing number of leading beverage brands who are going "back to glass" to convert their product lines into something more environmentally-friendly. Their secret weapon? An automated bottle filling machine capable of bearing the production rate.
Here are the main reasons why a growing number of companies are introducing automated bottle filling machines in their beverage bottling lines.
Why you should install an automated filler in your line
There are three main advantages due to a filler, such as a flavor drink filling machine, installed in the factory. Let's go through them together.
An automated filler increases the perceived beverage quality
Add a glass line to make your products more appetizing.
Glass bottles are associated with quality and "premium beverages" by most consumers. Think about it: When you sip a Coke or a soft drink from a glass bottle, doesn't it seem better than when you drink it from a plastic bottle or can?
This phenomenon occurs mainly because:
Glass does not release unwanted substances into the beverage;
The perception of flavor changes when drinking a soft drink directly from a bottle because the flow that reaches the tongue is directed to the receptors most sensitive to sweet taste;
Plastic is much more permeable to CO2 than glass, which means that carbon dioxide, or fizz, will be released from a plastic bottle much faster than from a glass bottle or can.
Consequently, we subconsciously associate drinking from a glass bottle with something of above-average quality.
If we add the fact that a high-quality automated filler does not affect the flavor of your beverage during bottling, you can really sleep soundly.
Glass bottles can be returned and reused
An automated bottle filler, such as flavor drink diamond carton filling machine, allows the bottling materials to be reused.
As we have repeatedly pointed out in our articles, glass is among the most sustainable materials available, because it can be 100% endlessly recycled, despite plastic.
Glass bottles can be returned, with an advantage of accessibility and sustainability to both consumers and producers.
With an automated bottle filler, you too will help support the circular economy and the well-being of the planet.
An automated bottle filler ensures financial success and a better image
Gain popularity with a glass-bottled beverage line.
Alcoholic and non-alcoholic beverage companies that opt for glass profit experience a more positive perception of the brand image. Such a choice, in fact, draws the attention of those who appreciate environmental sustainability or look for a more sophisticated beverage.
The consequence is quite logical: the more you become popular, the more financially successful you are through increased sales.