All Fill General Overview
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Transcript of All Fill General Overview
Equipment Capabilities
®
®
Engineered to ExcelBringing unsurpassed accuracy, efficiency,
reliability & support to your packaging system
Expertly crafted to your specifications by the leading minds in filling technology,
ALL-FILL fillers and filling systems bring you the perfect blend of precision, speed
and versatility. From concept to installation and beyond, ALL-FILL’s unique team
of in-house engineers and technical specialists becomes your personal filling
‘think tank’ - a continuing resource for optimizing performance and productivity
over the life of your equipment.
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®
AF-1105-E | Page 1
Table of ContentsSemi-Automatic Auger Fillers
Semi-Auto Fill-To-Weight Auger Fillers
Automatic Auger Fillers
Auto Fill-To-Weight - Millennium Series
Automatic Fill-To-Weight Auger Fillers
Multiple Ingredient Fill-To-Weight Systems
Multiple Auger Fillers
System Integration
High Speed Rotary Filling Systems
Filling & Checkweighing Systems
Model TA Twin Auger Fillers
Volumetric Cup Fillers
Volumetric Piston Fillers
Bulk Product Handling
Horizontal Net Weigh Filler
Miscellaneous
Retrofits
Filling Machine Tooling & Applications
AF-1105-E | Page 2
Semi-Automatic Auger Fillers
ALL-FILL’s field-proven semiautomatic
fillers excel in a wide variety of
applications with virtually any type
product. Typical models consist of a
sturdy, cast aluminum head containing
the drive components and a stainless
steel column mounted on a rugged
aluminum column. Controls offered
include a variety of PLC-based
packages, which can include a
“keypad” or “touchscreen” operator
interface. ALL-FILL semiautomatic
models can be seamlessly integrated
with packaging equipment such as
Form-Fill-Seal, Cup Filling and
Thermoformers. They can also be used
for stand alone, benchtop filling.
Standard configurations can be easily
adapted to your individual
requirements.
®
Model B-350e with
Keypad Interface
Support Frame with
Filler Height Adjustment
(Casters Available)
Model B-600 with
Touch Screen
Model B-SV-600
Model CF-SV-600
Semi-Automatic Auger Filler
Powder Filling
Stainless steel augers dispense product
from within a large capacity hopper. Variety
of accessories for filling freeflowing and
non-free flowing powder and granular
products.
Liquid Filling
Alternative, progressive cavity pump
installed on a drive shaft for dispensing
viscous liquids, creams, gels, etc.
Product Supply
Stainless steel 10 or 16 gal. Hopper
provides ample capacity and sufficient head
pressure for repeatable, accurate filling. A
self-aligning, “Quick-Disconnect” coupling
on the hopper allows fast removal and
replacement for cleaning or product
changeover.
Product Agitation
High and low speed agitation accessories
move product evenly into the auger flights.
High speed agitator blade (when required)
installed directly onto auger shaft. Slow
speed agitation driven by separate motor &
gearbox.
Product Level
Optional Level Controls available to provide
high/low detection of product in the hopper
with actuation to external equipment for
re-supply. Control and sensor assembly
easily mounted in hopper cover.
®
Specification SummaryDispensing Control
Optical shaft encoder provides 200 pulses
per revolution to controller for precise
control of auger revolutions. Alternative
Time Mode control provided as backup to
continue production in case of encoder
backup to continue production in case of
encoder failure.
Mounting
Standard cast aluminum bench/floor base,
with or without lockable casters. Also
available for direct mounting on
Form-Fill-Seal machines and other
packaging line equipment.
Fill Drive Systems
Clutch Brake: Standard 3-step belt drive
with 1-1/2 HP, 1200 RPM fill motor. Integral
electro-magnetic Clutch/Brake controls
shaft movement.
Servo: Model SV: Servomotor models
include brushless ac direct servomotor
drive.
Electrical
Fill Motor Input: 208/230/460V; 3-Phase;
60 Hz. Standard. Controls: 115V 50-60 Hz.
Other ratings upon request.
AF-1105-E | Page 3
Semi-Auto Fill-To-WeightAuger Fillers
Semi-automatic Fill-To-Weight
Auger Fillers are used when a
specific, verified, weighed
quantity of product is to be
dispensed. Models include
scales and loadcell components
to determine an accurate
weight reading before, during,
and after each fill cycle.
Accessories, such as Bag
Clamps, Roller Conveyors, and
Lifts are implemented according
to specific requirements and
constraints. Sophisticated
feedback/feedforward controls
allow for fill value adjustment,
error correction, and
accept/reject tolerance control.
®
Model BS with Roller Conveyer
Scale and Pneumatic Lift
Model BS with Roller Scale,
Electric Ball Screw Lift,
Dust Shroud and PLC
Controls
AF-1105-E | Page 4
er Scale,
Lift,
LC
Model BS with Load Cell, Bag
Clamp and Metal Detector
Model BS with Load Cell, Lift
and Inflatable Bag Clamp
Bag
Lift
Weighing Systems
Separate floor/tabletop Platform Scale or
combination Bag Clamp/Loadcell Scale
assemblies for accurate weight control of
containers and filled product.
Fill-By-Weight Control
Available Fill-By-Weight modes include:
Bulk & Dribble: Specifies filling &
weighing in a two-stage fill cycle where the
greater portion of product is dispensed,
weighed, then filled again to a desired
target weight. After the second, dribble-fill,
the container is weighed again and is
categorized as “Acceptable”,
“Underweight”, or “Overweight”.
Applications: High Accuracy, Low
Production Rates, Consistent Product
Density, Semi-Automatic operation requires
operator.
Setpoint: Specifies filling & weighing in a
single stage fill where product is dispensed
as its weight approaches a user-defined
target weight. Product weighed at the end
of fill and categorized as “Acceptable”,
“Underweight”, or “Overweight”.
®
Specification Summary
Applications: Moderate
Accuracy/Moderate Production Rates
(higher than Bulk & Dribble). Used with
product that changes density.
Semi-Automatic operation requires an
operator.
Fill By Time: Specifies filling only. No
weighing occurs. Product is dispensed for a
user-specified fill time. Bypasses loadcell
and encoder in cases of failure/malfunction.
Applications: Accuracy dependent on
product density. High production rates.
Capable of fully automatic operation without
operator intervention. Allows production to
continue with loadcell/encoder failures or
malfunctions.
Fill By Revolutions: Specifies filling only.
No weighing occurs. Product is dispensed
for a user-specified number of auger
revolutions. Bypasses loadcell in cases of
failure/malfunction.
Applications: Accuracy dependent on
product density. High production rates.
Capable of fully automatic operation without
operator intervention. Allows production to
continue with loadcell failures or
malfunctions.
AF-1105-E | Page 5
Semi-Auto Fill-To-WeightAuger Fillers
AF-1105-E | Page 6
Automatic Auger Fillers
ALL-FILL Automatic Auger Fillers
are designed for complete,
continuous container transport,
positioning, filling, and discharge
to the next stage in the
packaging process. Automatic
models combine a standard fill
head with an integral conveyor to
move containers. Indexing
system mounted on conveyor
regulates container movement
toward the filling position,
centers each container for filling,
then moves the container away.
Available in single or multiple
head configurations, automatic
models can be equipped with a
variety of accessories and
options to suit particular
container handling or product
characteristics.
®
Model SHA Single Head AutomaticModel SHA Single Head Automatic
Model DHA Dual Head AutomaticModel DHA Dual Head Automatic
Automatic Auger Filler
Base
Tubular frame with removable access
doors. Includes mechanical jack to
raise/lower fill head.
Conveyer
Stainless Steel Conveyor Channel with dual
strand, stainless steel block conveyor chain
or plastic table-top conveyor, adjustable
guide rails, and variable speed conveyor
drive. Pneumatic Container Indexing with
Round End, Cone Point, Wedge Stop, or
Pressure Stop adjustable Indexing Pins.
Options
Available options include, but are not
limited to:
®
Specification Summary
AF-1105-E | Page 7
Slow Speed Agitation with separate motor,
reducing gearbox, and drive components. Includes
stainless steel slow speed agitator blade.
Pneumatic or Hydraulic Container Lift to
raise/lower container to funnel.
Adjustable speed, jogging Container Vibrator to
settle and distribute product in container.
Product Cutoff device with time/limit switch
actuation.
Raise/Lower Filling Nozzle (air-operated).
Container Clamp to secure container during filling.
Electronic Scale for filling amount adjustment.
Off-line Scale with Feedback
Servo Motor DrivenAutomatic Auger Fillers
®
Model SHA-SV Single Head
Servo Automatic
Model DHA-SV Dual Head
Servo Automatic
AF-1105-E | Page 8
®
AF-1105-E | Page 9
Auto Fill-To-Weight - Millenium Series
As the name implies, the
Millennium Series of Auger Filling
Systems offered by ALL-FILL sets
the standard for state-of-the-art
filling technology for the new
millennium. The “dual lane”
systems promote product flexibility
and maximum manpower
utilization due to the independent
lane options and ergonomically
sound layout of system
components. Totally automatic
systems are available with scale
feedback, servomotor timing screw
container handling, product lifting,
container opening devices, and
servomotor auger drives to ensure
a clean, accurate fill - at speeds
that will keep you competitive in
the new millennium!
®
Multiple Auger Bulk and Dribble Filling System
Timing Screw Positioning and Weighing
Multiple Auger Bulk and Dribble Filling System
Automatic Fill-To-Weight Auger Fillers
®
Dual Head Bulk & Dribble System
Model DHAS Dual Head Servo Drive Filler With Scales and Reject Station
AF-1105-E | Page 10
Model DHAS Dual Head Automatic FillerModel DHAS Dual Head Automatic Filler
Model DHAS Dual HeH ada Servo Drive Filler With Scales and Reject Station
DuD al Head BuB lk & Driibble System
Multiple Ingredient / Fill-To-WeightSystems
®
Multi-Ingredient Packaging Line - With ALPHA Checkweigher and Avatar Bagger
AF-1105-E | Page 11
Multi-Ingredient Packaging Line - With ALPHA Checkweigher and Avatar Bagger
AF-1105-E | Page 12
Multiple Auger FillersALL-FILL’s Multiple Auger Systems provide controlled, multiple auger dispensing of product across a
production line encountered with Cup machines, Form-Fill-Seal equipment, Thermoformers, and
Strip/Pouch machines. Filling positions can range from 3 to 12 across with a minimum center
distance of 1-3/4”. Multiple Auger models are available in Baseplate, cantilever, or overhead Gantry
mounting configurations to best suit the equipment or application. Individual Servo Drives are
independently adjusted. 360 degree Agitation available (3-1/2” Centers and up). Multiple Auger
model can be mounted and installed onto production equipment at ALL-FILL for thorough
integration and testing. (See System Integration - pages 14 and 15).
®
Twin 12 Spindle Direct Drive Servo System With Raise / Lower Assembly
Multiple Auger Fillers
®
Three Spindle, Column Mounted Multiple
Auger System
Four Spindle, Frame Mounted
Multiple Auger System
AF-1105-E | Page 13
®
AF-
1105-E
|
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AF-
1105-E
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AF-1105-E | Page 16
High Speed Rotary Filling SystemsALL-FILL Rotary Fillers provide high throughput and speeds for even the most demanding
production environments. Rotary filling systems operate continuously with product dispensed into
funnels traveling on a circular, multi-position turret. Containers are transported to the turret by an
integral infeed conveyor. Timing screw and starwheel components space and position containers
into the turret. variable speed auger drives operate continuously to dispense product accurately.
Product weight is easily adjusted by the operator or from checkweigher feedback signals.
Production rates (c.p.m.) are adjusted by varying turret speeds.
®
Twin Head 45 Station Configuration
Dual Head 30 Station Configuration -
With ALPHA PW-12 Checkweigherg
High Speed Rotary Filling Systems
Fill Drive System
Single or twin 2hp drive motors with variable speed motor
and heavy-duty clutch/brake per head. Drive system
components contained in rugged, cast metal head.
Container Sizes
14” pitch diameter starwheel (12-Station): 2 3/16” dia., max.
30” pitch diameter starwheel (12-Station): 4 1/2” dia., max.
36” pitch diameter starwheel (18-Station): 5 1/2” dia., max.
40” pitch diameter starwheel (18-Station): 6 1/4” dia., max.
38” pitch diameter starwheel (24-Station): 4 1/4” dia., max.
42” pitch diameter starwheel (24-Station): 5 1/8” dia., max.
38” pitch diameter starwheel (30-Station): 2 3/4” dia., max.
(Other sizes available upon request)
Base
Fully enclosed, painted mild steel base cabinet with
removable access doors, stainless steel top, and mechanical
jack to raise/lower fill head.
Conveyor
Stainless steel (Type 304) Conveyor Channel with acetyl
flat-top chain and variable speed dc drive motor with
reducing gearbox, chain sprocketing, and drive components.
Turret
12-45 Position fixed Turret Assembly with Divider Plate &
®
Specification Summary
AF-1105-E | Page 17
Funnel Carriage. Includes variable speed drive, turret jam
protection, vacuum take-off ports at each fill position, turret safety
shroud assembly with front access panels, and safety interlock
switches.
Container Handling
Systems include one complete set of container handling parts
supplied, including:
Container Positioning
FInfeed Timing screw positions container at infeed. Removable
starwheel moves containers to Turret positions.
Vibration
Variable frequency, variable amplitude square wave vibration to
settle and distribute product into container during filling.
Options
Options include, but not limited to:
Infeed & Outfeed starwheels
Outer Guide Rails
Infeed Guide Rails
Removable main starwheel segments
Timing screw & adapter
Intermediate guide
Anodized Head Assembly
Stainless Steel Covers
Vented Cover
Quick Clamp Assemblies
D.C. Drive/Agitation Motors
Electrical Jack Assembly for
raising/lowering fill head
Height adjustable Turret / Funnel Carriage
assembly
PLC Computer Controls with feedback
capability
Motorized Potentiometer for Servo feedback
Clean-In-Place (C-I-P) blowdown system
AF-1105-E | Page 18
Filling & Checkweighing SystemsThese adaptable combination systems allow filling accuracy and productivity to be enhanced while
avoiding the problems and incompatibilities encountered by joining filling and checkweighing
components from separate sources. weights detected by checkweighers in these models can be
used as feedback that adjusts amounts dispensed at the filler. These systems have proven to be
particularly useful in applications where a large number of products are used with a number of
different containers, such as contract packaging.
®
Model SHA With ALPHA CW-10 Checkweigher
AF-1105-E | Page 19
Filling & Checkweighing Systems
®®
Triple Head 24 Station Rotary Filler with
ALPHA Model MW-16 Checkweigher
Model TA-600 with Model CW-10
Checkweigher
AF-1105-E | Page 20
Model TA Twin Auger Fillers
ALL-FILL Model TA Twin Auger
Fillers are designed for high
speed/high volume dispensing
typically encountered in vertical
form-fill-seal, cup filling, or other
applications requiring dual position
filling. The standard Model TA
offering consists of dual fill motor
and drive assemblies and a high
capacity, stainless steel product
hopper mounted on a variable
length column with either a floor
base, or a 10” dia. round base for
direct mounting on other
equipment (e.g., form-fill-seal
machines). Your filling application
specifies each Model TA Unit.
Center distance between the two
augers can range from as little as
2” to well over 16”.
®
Model TA Twin Auger
Filler
Model TA-SV Servodriven
Auger Filler
AF-1105-E | Page 21
Volumetric Cup Fillers
®
Model VC-SV-4
Volumteric Cup Filler
Model VC-100-2
Volumetric Cup Filler
All-Fill Volumetric Cup Fillers set
a new standard for free flow
product filling applications. Used
for dispensing granular, seeds,
popcorn, rice, beans, gravel,
candies, and many others.
Toolless cleaning and changeover
design adds speed and flexibility.
Additonally, the All-Fill line is
manufactured with all stainless
steel and toher approved product
contact parts to meet packaging
regulation in all industries.
Standard PLC controls, touch
screen interface, and integral
servo gearmotor-these systems
are designed to run flawlessly in
production up to 100 CPM.
AF-1105-E | Page 22
All-Fill offers a line of Vibratory
Filler designs as an alternative to
its auger filling equipment. These
Vibratory Filler designs are
particularly well suited for products
that could become damaged when
filling with rotating auger
equipment and other types of
free-flowing products such as
whole bean coffee, small nuts, rice,
grains, confection items, and
others.
A matched pair of electromagnetic
vibrator and vibrating tray
transports the product to a weigh
bucket. A loadcell attached to the
weigh bucket determines
accumulating weight. When the
desired amount in attained, the
gate opens to dispense product
through the discharge funnel.
®
AAllll-FFiillll offffers a lliine off VViibbratory
Vibratory Fillers
VF-100-ST
VF-200-ST
Vibratory Filler Rigidized DetailVibratory Filler Rigidized Detail
Vibratory Filler Head Detail
VF-115 VF-200-SYS
®
AF-1105-E | Page 23
Vibratory Fillers
VF-115
Volumetric Piston FillersLiquids, creams, pastes, and other viscous
products can be filled using ALL-FILL’s line of
volumetric piston fillers. Models are available
to dispense ranging from less than an ounce
to over a gallon per cycle. A wide range of
accessories are offered, including cutoffs,
conveyors, container handling packages, etc.
All pneumatic operation and stainless steel
construction make these models ideal for
washdown food/dairy applications and
hazardous environments.
®
Model 305 Piston Filler - With Hopper
AF-1105-E | Page 24
Model 305 Piston Filler - With Hopper
Model 505 Piston FillerModel 305 Piston Filler - With Direct Product Feed
Model 545 - 4 Head Horizontal Piston
Filler with Conveyor
Model 545 - 4 Head Horizontal Pist
Filler with Conveyor
Series 1500 Model 1545 - 4 Head
Vertical Automatic Piston Filler
ton
Model 205
Compact, small capacity single
nozzle filler for small fill quantities of
cosmetics, pharmaceuticals, etc.
Fill Range: 0.169 oz. To 1.69 oz.
Cylinder Sizes: 1 1/2" dia.,
standard. 1/2" dia. available
Features: Compact size well suited
for tabletop/bench top operation.
Built-in cutoff assures clean fills
Model 305
Single nozzle piston filler with rotary
valve for universal applications -
Totally pneumatic
Fill Range: 1/3 oz. To 87 oz.
Cylinder Sizes: 1", 1 1/2", 2", 3", 4
3/4" dia.
Features: Dual speed filling for
greater control. 305A-D variations for
dispensing directly from bulk source.
Convenient front panel volume
adjustment, auto recycle.
®
Model 505
Heavy duty, low capacity, single
nozzle filler for liquids, creams, and
pastes with particulate matter
Fill Range: 8 oz. To 1.16 gal. (5 L)
Cylinder Sizes: 4 3/4" dia.,
standard. 3", 6", & 6 3/4" dia.,
available
Features: Large port rotary valve
accommodates particles up to 0.8"
dia. Variations available for greater
capacity and multiple positions for
full automatic operation
Series 1500
Fully automatic, multiple nozzle filler
designed for high speed production
Fill Range: 17 oz. To 2.6 qt.
Cylinder Sizes: 2 1/8" dia. to 4
3/4" dia.
Optional Features: Dual speed
filling for greater control. Nozzle side
shifting and Drip Pan reduce waste.
Individual nozzle adjustment. Diving
nozzle for bottom-up filling.
AF-1105-E | Page 25
Volumetric Piston FillerSpecification Summary
Bulk Product Handling
In addition to the filling and
checkweighing equipment presented
herein, ALL-FILL can also supply the
following to complete or enhance
your filling, weighing, or packaging
operation. From Screw Conveyors to
refill filling machine hoppers, to
Rotary Unscrambler and
Accumulating Tables, Pump Fillers
and Weigh Bucket fill-to-weight
accessories, ALL-FILL can bring its
engineering experience and
innovation for your specific needs,
requirements, and application.
®
Model ISC Inclined Screw Conveyor
AF-1105-E | Page 26
Modell ISC Innclc innedd SScrcrewew Conveyoy r
ents, and application.
Model FSC Flexible Spiral Conveyor
Model ISC Inclined Screw Feeder
AF-1105-E | Page 27
Horizontal Net Weigh Filler
®
Horizontal Net Weigh FillerHorizontal Net Weigh Filler
AF-1105-E | Page 28
Miscellaneous
®
Rotary Unscrambler TableRotary Unscrambler Table Rotary Accumulator Table
Weigh Bucket
Vacuum-Assisted
Filler With Indexing Timing
Screw
Pump Filler
RetrofitsIn addition to our product lines,
ALL-FILL provides complete
filler overhaul services to put
your used equipment into new
condition. If your requirements
include servos, ALL-FILL can
replace your old clutch/brake
with a servo powered unit. Work
can be accomplished at
ALL-FILL or in the field. Allow
ALL-FILL to upgrade your
existing system to meet your
ever-changing needs.
®
AF-1105-E | Page 29
Before
After
®
Filling Machine Tooling & Applications
Accessories supplied with
ALL-FILL Filling Machines are
used for products with different
filling characteristics for the
most efficient use of the
machine. The following lists
typical applications of filling
accessories available for auger
fillers. The mechanical
configuration of accessories
installed on an auger filler for
different types of products is
presented on this page.
®
AF-1105-E | Page 30
Filling Accessory ApplicationsProduct
Bakery Mixes, Carbon,
Talcum Powder, etc.
Examples Accessories
Non-Freeflowing Powders
Freeflowing Products
Liquids and Pastes
Granulated sugar, salt,
bread crumbs, etc.
Slow Speed Agitator, High
Speed Agitator (Type D),
Self-Feeding Auger, Lip
Funnel. For products that
drip slightly at the end offill,
Drip Washer can be used.
Straight Auger, High Speed
Agitator (A-3), Slow Speed
Agitator or Flake Blade,
Straight Funnel, Collector
Funnel Cover, Spinner
Plate, Dividing Head (2 or
more containers per fill for
borderline products), Type
D High Speed Agitator, Lip
Funnel.
Creams, Shampoo,
Oils, Gels, etc.
Rotor, Stator, and Pump
Housings (1-4), Dispensing
Nozzle, Cutoffs.
Accessories used with a particular filling
machine will depend on a variety of factors,
including: Product Flow Characteristics and
Density, Filled Amounts, Container Size &
Configuration, Filling Times, and Accuracy.
Before making the final selection and setup of
accessories, the product and container should
be tested to ensure that the machine will fulfill
your requirements. ALL-FILL offers thorough
testing services and facilities for the analysis
of products and suitability of accessories.Freeflowing
Liquids and Pastes
Non-Freeflowing
Our fillers haveminds of their own
With ALL-FILL, you’re never alone. Our
unique team of in-house engineers and
technical specialists works with you,
shoulder to shoulder, crafting tailor-made
technology to precisely meet your individual
specifications. Bringing you a line of fillers
that are smarter, faster and more versatile
than ever, the ALL-FILL System can be your
key to maximizing productivity, intelligently.
®
Each ALL-FILL Filler comes with a
personal think tank for maximizing
performance.
Manufacturing bases
Countries served by ALL-FILL
Countries served by ALL-FILL International,
our United Kingdom based sister company
ALL-FILL Worldwide Network
Expertly engineered by the leading minds in filling technology,
ALL-FILL filling solutions propel packaging systems into new
realms of efficiency, accuracy and reliability. Each filler and
filling system is intelligently designed for seamless integration
into even the most complex packaging environment, while
maintaining the flexibility to grow as you do. ALL-FILL’s
unparalleled “Think Tank” support empowers you with a team
of filling engineers and technical specialists to ensure your
operation reaches its fullest potential for productivity and
profitability.
®Filling the need for added performance and reliability
418 Creamery Way
Exton, PA 19341 U.S.A.
1-866-ALL-FILL • Fax: 610-524-7346
[email protected] • www.all-fill.com
© 2011 ALL-FILL, Inc. - AF-1105-E