Lesson 9 Filling Systems - Shandong University...Piston Volumetric Filling A piston filler (Figure...

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Lesson 9

Filling Systems第9课充填灌装系统

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content

Introduction Liquid Filling Liquid Volumetric Filling Liquid Constant Level Filling Dry Product Filling Dry Volumetric Filling Dry Filling By Weight Filling By Count

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Introduction

1. What a filler can be asked to do?Fillers, filling machines, are used to transfer manytypes of products from bulk storage bins and vatsinto the containers in which they find their way tothe market. The great variety [vəˈraiəti] of productsthat are packaged and the containers that they fillhas caused the development of a large number ofprocesses, techniques, and machines that areused for product filling.


2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid

products, pastes [peɪst] , and solids; stable, volatile,explosive, hot, frozen products.

Size, shape, and construction of the containers:glass bottles and jars, plastic bottles and cartons, paperboardboxes, metal cans, and plastic or paper bags.

Way the product is measured: by volume, weight, orcount.

Introduction


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Introduction

Desired speed of the operation: a relatively slowmanual operation, semi-automatic, fully automatic ( highspeed lines)

Special handling requirements of the product Cost of installation Operation


Liquid Filling

1. Introduction

Liquid products: alcohol and soda water

Semi-liquid products: toothpaste, peanut butter, and caulking compound

['tu:θpeist]

Waterproof material used to seal joints at intersections of building components


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Liquid Filling

2. Types of Filling Machines

The containers may be made of plastic, metal,glass, treated paperboard, or a number of othermaterials.

The shapes of the containers include those ofbottles, jars, vials|| 'vaɪəl]小瓶, tubes, cans,pouches, cartons, and drums (Figure 20.1).


Figure 20.1 The shapes of the containers

Liquid Filling


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Most liquid and semi-liquid products are filled byone of two major methods: volumetric, or constantlevel filling.

In volumetric filling the amount of product ispremeasured so that each container has thesame volume of product.

Constant level filling techniques fill eachcontainer to the same level, so it is frequentlycalled the “fill-to-a-level” method.

Liquid Filling


Liquid Filling

3. Use of Filling Machines Volumetric filling is particularly appropriate for

applications in the pharmaceutical industry whereit is important that each container is accuratelyfilled with a specific volume of product.

Constant level filling is used with see-through 看穿bottles in which it is important that all of the bottlesin a display appear to be filled to the same level,although the bottles may not be exactly the samesize and the volumes may be slightly different.


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Liquid Filling

4. Rotary and Straight-line FillersThe rotary filler removes the containers from the conveyoronto a rotating plate which carries them in a circle throughthe filling machines. The filling heads rotate with thecontainers as they are filled, so that there is a continuousmotion (Figure 20.2).

Figure 20.2 Rotary filling

动画


Liquid Filling

The straight-line fillers fill each container as itmoves along the conveyor in a straight line.a) This may be an intermittent motion operation inwhich the conveyor is stopped until the containeris filled, then it is moved just far enough to placethe next container in position under the fillingnozzle.b) It may fill only one or a number of containers ineach operation depending upon the number offiller heads that are used.


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Liquid Filling

c) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).

Figure 20.3 Straight-line filling

动画


Liquid Volumetric Filling

Introduction Definition: Volumetric fillers deliver a premeasured

volume of product to each container, and the volume ofproduct in each container is held constant.

Advantages: accuracy, flexibility, and reliability inaddition to being relatively easy to clean.

Three popular types of volumetric fillingmethods: piston operation, diaphragm action, and timedflow.

diaphragm [di·a·phragm || 'daɪəfræm]n. 横隔膜, 光圈, 隔板


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1. Piston Volumetric FillingA piston filler (Figure 20.4) measures and deliversthe product to the container by the action of a singlepiston for each filler head.

Empty Filling

Figure 20.4 Piston volumetric filling with rotary valve



Figure 20.5 Piston volumetric filling with re‘ciprocating valve动画


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Types of valves: a reciprocating valve and a rotating valve (Figure 20.6).

Rotary valve Reciprocating valve

Figure 20.6 Valves

[vælv]



The volume of product delivered into the containeris determined by the volume of the filling chamberin which the piston is operating. This volume canbe changed by adjusting the length of the piston’sstroke. As the stroke is lengthened, the volume ofthe chamber is increased, and as the stroke isshortened, the volume of the chamber isdecreased (Figure 20.7).


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Short piston stroke Longer piston stroke

Figure 20.7 Volume adjustment

动画



Figure 20.8 shows three methods that areused to keep the product from leaking outaround the piston as it moves back andforth: fine tolerance, rings placed in grooves凹槽around their cir’cumference and cuffs封套 appliedto the ends of the pistons to create a seal.


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Machined surface Rings Cuffs 袖口（端部处理）

Figure 20.8 Three methods to keep product from leaking out around piston



Different types of products require different nozzledesigns and sizes (Figure 20.9).

Filler nozzles are designed in different sizes andshapes to prevent splashing 飞溅 , foaming, orexcessive aeration 通气 of the products duringfilling.

[ˌeiə'reiʃən]


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Figure 20.9 Nozzle types

动画 1 动画 2 动画 3 动画 4



2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses

a flexible diaphragm and pneumatic pressure tomove premeasured amounts of product from thesupply tank into a controlled volume chamber andinto the container.

The diaphragm volumetric filling systems aregenerally used to fill small-necked bottles withrelatively expensive products because of theirhigh level of accuracy and the small loss ofproduct in filling.

['daiəfræm]


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Figure 20.10 Diaphragm volumetric filler 动画



3. Timed Flow Volumetric Filling The volume of product in each fill can also be

regulated by controlling the amount of time theproduct flows at a constant rate through astandard sized tube into the container.

Three popular ways of measuring and regulatingthe flow time are rotating metering discs, rotarypumps, and augers螺旋.


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1) Rotating Metering Discs The filling head consists of two stationary

plates and a bottom rotating plate (Figure20.11).

When the openings in the three plates are inalignment, the product is free to pass throughinto the container. The flow ceases when therotating bottom plate moves out of position.



StationaryTop PlateStationaryTeflon PlateRotatingBottom Plate

Filling FilledFigure 20.11 Rotating metering discs


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The volume of the fill can be regulated by changingthe size of the opening, or slot, in the center plate orby changing the speed of the rotating plate.

This filler can double fill a container by passing itunder two stations, or two or more differentmaterials can be filled into the container bysupplying different products at the different fillingstations.

The volumetric filler using metering discs can handlea wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.



2) Rotary PumpsRotary pumps (Figure 20.12) are used for volumetric fillingby regulating the operating interval of the pump to controlthe amount of product that is delivered.

Figure 20.12 Rotary pump filler 动画


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The product flow is controlled by electric or airoperated clutch and brake mechanisms that canstart and stop at very precise intervals.

Some fillers measure the product flow with arevolution旋转 counter attached to the drive shaft ofthe pump, and the flow is regulated by adjusting thenumber of turns that the pump impellers make oneach fill.

shaft [ʃæft /ʃɑːft]n. 轴, 杆状物



3) Augers Semi-liquid products that are too thick to be moved

by a rotary pump may be filled by a similar filler thatuses an auger in place of the pump to move theproduct.

The volume of product delivered by an auger filler(Figure 20.13) is controlled by the amount of time theauger turns or the number of turns it makes on eachfill, in much the same manner that is used for rotarypumps. || 'ædʒɪteɪtə(r)]

Some auger fillers use an agitator rotating in theproduct hopper to keep the product moving smoothlyand maintain an even consistency.

搅拌器www.dplab.sdu.edu.cn

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Figure 20.13 Auger filler


Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the

same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf.

Some manufacturers deliberately add extra product and overfill some of their “see through” containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product.

Constant level filling techniques ‘compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in “see through” containers.

慎重地; 故意地


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Liquid Constant Level Filling

Five basic methods used for constant level filling of still 无气的不起泡的 liquids and semi-liquids:

Pure gravity fillingPure vacuum filingGravity vacuum filingPure pressure fillingLevel sensing filling

One method used for filling carbonated products:Pressure gravity filling



1. Pure Gravity Filling Being not only one of the oldest and simplest

constant level filling methods, but it is also one of themost accurate ones for filling free-flowing products(Figure 20.14).

Used for most still liquids and some semi-solids. The product flow is produced by locating the product

supply tank high enough so that forces of gravity canbe used to move the product through the feedmechanisms into the containers.


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Figure 20.14 Pure gravity filling 动画



The maintenance requirements arerelatively simple.

The con’sistency of the product and the freemovement of all moving parts are critical forsmooth operation.


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2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles

with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid

containers. Generally faster than a pure gravity system, but has

some overflow and recirculation回流 of product. Thevacuum filler works only when there is a sealbetween the bottle and filler valve, so chipped orcracked bottles can not be filled. 在...上造成缺口



Figure 20.15 Pure vacuum filling 动画


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A vacuum level of between 25 and 28 inches ofmercury is normally maintained to provide smoothand efficient operation.

Somewhat稍微有点 more difficult to clean than asimple gravity system because of its complexity andsmall vacuum tubes that can become plugged.

The proper type of filling nozzle is always used forthe product being filled, because foaming, aeration充气, and splashing溅 can be increased by rapidmovement of the product.

/mɜː'kjʊrɪ]n. 水银,



3.Gravity Vacuum Filling Combining the features of both the gravity and the

vacuum systems (Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is

maintained in the system to assist in drawing the airout of the containers and to stabilize the flow of theliquid.

Having not the overflow or recirculation of productthat is inherent固有的 in the pure vacuum system,and it produces minimum amounts of turbulence andaeration of the product.


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Particularly well suited to filling distilled 蒸馏的spirits精神酒精 and wine becausethere is virtually 事实上no loss of proof 酒精度.

A chipped or cracked bottle on which aseal is not formed will not be filled.



Figure 20.16 Gravity vacuum filling


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4. Pure Pressure Filling The product is pumped from a storage tank through

a filling valve and into the container (Figure 20.17).

Figure 20.17 Pure pressure filling 动画



When the product reaches the overflow port, thefill is completed, but the flow continues through theoverflow tube until the valve sleeve 套管 coversthe ports in the filling nozzle and stops the flow.

Normally used for still liquids, but it can be appliedto a wide variety of products with differentconsistencies.


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Applying pressure to the product may tendto increase splashing or foaming.

Regular cleaning and lubrication of allmoving parts.



5. Level Sensing Filling Making it possible to fill containers to a level without

establishing an airtight 密闭的seal between the tops of the containers and the filler valves (Figure 20.18).

Figure 20.18 Level sensing filling 动画


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Used primarily for high speed filling of small neckedplastic and glass bottles.

The fill level is very accurate, and there is no need forproduct recirculation.

The sensing device operates by directing a stream oflow pressure air at the filling station and detectingchanges in the resistance to the air flow.

The positioning of the filler and the start of the flow canbe initiated when the sensing device detects thepresence of the empty bottle in the filling station.When the product has filled to the desired level, thesensing unit signals the interface valve to stop the flow.

start 接口阀www.dplab.sdu.edu.cn 50


6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process

that was developed specifically to help hold the CO2in the carbonated beverages during the fillingoperation.

This method is used almost exclusively专门地 forfilling beverages such as sodas, beer, sparkling 起泡沫的wines, and champagnes into bottles or cans.

A pressure of between 15 and 125 psi is main’tainedin the headspace of the product supply tank to helphold the CO2 in solution.

|| ‚ʃæm'peɪn] 起泡酒，汽酒

Pounds per square inch gauge.


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Filling Filled

Figure 20.19 Pressure gravity filling 动画



When the container is sealed to the fillingvalve a mechanical latch 碰锁 opens acharging valve at the top of the valve venttube. This establishes in the container thesame pressure level that is being applied tothe surface of the product in the supply tank.The product is in a totally pressurizedenvironment. This pressure does notinterfere with the filling process, but it doesprevent the loss of carbonation.

碳酸饱和; 碳酸化作用


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After the pressure in the container is equalized withthat in the supply tank, the spring loaded filler valveopens and the product flows into the container bygravity until the vent port is covered and the flow isstopped as in a normal gravity filling process.

The filling valve also contains a mechanical snift portwhich opens the headspace of each filled container tothe atmosphere in order to gently release thepressure from the filled container and prevent gushingwhen the seal is broken and the filler head is removedfrom the container.

吸入

gush [gʌʃ]n. v. 喷,


Dry Product Filling

1. Introduction Dry products: light, heavy, sticky, very dry, flowing

freely, some moved by force.

The containers: as small as a capsule or as large asa one hundred pound bag or a 55 gallon drum. They canbe boxes, cans, bottles, pouches, bags, drums, or otherforms, and they may be made of a variety of rigid andflexible materials.

US ˋkæpsl/


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Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move.

Fine powders (confectioners sugar), may be hard tocontain in the bins or containers and can cause adusty or explosive atmosphere.

Nails, bolts, and other hardware items may requirespecial handling because of their weight, bulk, orshape.

Cornflakes and light bulbs must be protected frombreakage during packaging.

Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging

sanitary and drugs sterile.

糕点、糖果制造人

干玉米片

|| 'sænɪtərɪ /-trɪ]adj. 公共卫生的; 卫生的; 卫生上的; 清洁的


Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines

based upon the way the amount of product beingdelivered is measured:

·By volume: the volumetric fillers deliver aconstant volume of product to each container.

·By net weight: the net weight filler weighs theproduct before it is delivered into the package.

·By gross weight: the gross weight filler weighsthe product in the container

·By count: the counter places the same numberof items into each container.


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Dry Product Filling

4. Product Delivery Free flowing dry products are frequently delivered to

the filling machine through gravity feed system. Other products are delivered by vibrator systems in

which vibrating pans cause the product to “walk” intothe filler.

Augers are used to move the nonfree-flowingproducts that are sticky or have other characteristicsthat make them difficult to handle.


Dry Volumetric Filling

Introduction Loading an exact volume of product into each

container without consideration of the product’sdensity or weight.

Delivering a constant volume does not alwaysproduce a constant weight.

Four popular types of volumetric fillers used withdry products are :

·Cup or flask fillers 细颈瓶

·Flooding or constant stream fillers·Auger fillers·Vacuum fillers.


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1) Cup or Flask Fillers Getting its name from the cup or flask that

is used to measure the amount of productthat is delivered (Figure 20.20). The sidesof the cups telescope so that the cup sizecan be adjusted to the exact volume that isneeded.

使套叠



Figure 20.20 Cup or Flask Fillers 动画

刮刀


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Dry Volumetric Filling Working particularly well with free-flowing granular

products. Normally used for products in which the density or

unit weight is relatively constant or when the volumeof the product that is delivered is more importantthan the weight.

Usually used when the size variations are relativelysmall or the gained speed and economy more thanoffset the cost of the extra product that is being used.

Figure 20.21 shows a top view of a twelve headrotary filler with a scale on one cup.

Machine adjustments may occasionally be needed tocorrect conditions of underfill, overfill, excessiverecirculation, or spillage at the container.

Vt, vi, n 抵销 www.dplab.sdu.edu.cn 62


Figure 20.21 Rotary filler with feedback scale (top view)


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2. Flooding or Constant Stream Fillers The fillers work on the principle that containers

passing under a constant stream of product in thesame amount of time will all receive the sameamount of product (Figure 20.22).

Any variations in the speed of the container as ittravels under the filler affects the volume of the fill.

Changes in the rate of product flow from the hoppercan also affect the volume of the fill.



Figure 20.22 Flooding or Constant Stream Filler 动画


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Dry Volumetric Filling3. Auger Fillers Use a rotating auger in a funnel shaped hopper to

deliver a specific amount of product at a constantrate(Figure 20.23).

The volume of the fill is determined by the extent ofthe rotation made by the auger.

Some auger fillers have timing mechanisms thatallow the auger to turn for a preset time on each fill,and other designs count the number of rotationsthat the auger makes on each fill.

funnel [fun·nel || 'fʌnl]n. 漏斗, www.dplab.sdu.edu.cn 66


Figure 20.23 Auger filler


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Used for a wide variety of products, but they areparticularly appropriate for products that tend tobridge over the openings, such as finely groundcoffee, cake mixes, and flour.

The auger shown in Figure 20.24 is used to movenonfree-flowing powders, and the auger shown inFigure 20.25 is designed to provide an even flow offree-flowing powders while preventing the naturalflow when the auger is not turning.

ground [graʊnd]

n. 土地, 场地, 战场v. 放在地上, 打基础, 使搁浅; 搁浅; 落地; 依靠, 基于, 根据

grind [graɪnd]

n. 磨, 研磨; 苦差使; 磨擦声; 单www.dplab.sdu.edu.cn 68


Figure 20.24 Auger fornonfree-flowing powder

Figure 20.25 Auger for free-flowing powder

动画


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4. Vacuum Fillers Similar to the fill-to-a-level operations used with

liquid products (Figure 20.26). They use the container as a measure of the fill. A

vacuum is used to draw off excess product and totamp the product for a tight fill or preventingproduct dust from escaping into the air.

捣实



Figure 20.26 Vacuum fillers for dry products


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Dry Filling By Weight

Introduction For some products the weight of the product in

each package is more important to the user thanthe volume, and the cost of the product may makeit uneconomical to deliberately overfill some of thecontainers in order to guarantee that they allcontain a minimum weight.

There are two basic techniques for filling by weight:net weight and gross weight filling systems.



1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling

machine before it is loaded into the container(Fig.20.27).

Easily used for filing bags and other flexiblecontainers that must be supported during the fillingoperation.


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Figure 20.27 Net weight fille 动画

receptacle [rɪˈseptək(ə)l]n. 容器



The accuracy of the net weight fill can be affected bythe amount of product in the stream when the shuttercloses to stop the fill.

A two-stage net weight fillers (Figure 20.28) are usedto increase their accuracy and speed. In the firststage the bulk of the fill is dropped rapidly into thechamber by a large filling spout, then the chamber ismoved under a smaller spout that dribbles in amountof product that is needed to complete the fill.

This type of system allows the container to be filledmore rapidly while keeping the amount of product inthe stream at a minimum when the shutter is closing.

dribble [drib·ble || 'drɪbl]n. 点滴, 少量, 口水

v. 滴下;shutter百叶窗, www.dplab.sdu.edu.cn

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Figure 20.28 Two stage filler


Dry Filling By Weight2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is

weighed inside the container as it is filled, and thescale operates a signaling device that operates thefiller.

Filling by gross weight is faster than by net weight,because it requires one less step.

It is also preferred for handling more fragile productssuch as cornflakes and potato chips that can bebroken or crushed by handling, since they can bemoved gently into the package without dropping themfrom one container to another.


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Figure 20.29 Gross weight filler



Some products, such as brown sugar, may need tobe settled into the package during the filling processin order to obtain a tight pack.


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Figure 20.30 Vibrating fill



Types of Scales The four types of scales commonly found on filling

machines are:Balance beam scale (Figure 20.31)Spring balance scale(Figure 20.32)Air balance scale (Figure 20.33)Liquid displacement 置换 scale (Figure 20.34)


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Figure 20.31 Balance beam scale



Figure 20.32 Spring balance scale

Figure 20.33 Air balance scale

Figure 20.34 Liquiddisplacement scale


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Filling By Count

Introduction Nuts, bolts, capsules, cookies, and a wide

variety of other products are marketed bynumber rather than volume or weight.

Four popular techniques are frequently usedfor filling products by count:

Board or disc countersSlat countersColumn countersElectronic counters.

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Filling By Count

1. Board or Disc Counters The product is dropped or brushed into a group of

holes in a disc or board and moved to a positionfrom which it is dropped into the container, thenumber of items in each fill is determined by thenumber of holes in the area of the board or disc thatis used.

This technique is widely used in the pharmaceuticalindustry for filling containers with tablets.


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Filling By Count

Figure 20.35 Disc counter


Filling By Count

2. Slat Counters.

The slat counter is a chain driven conveyormade up of slats which have pockets orcavities to hold product items (Figure20.36).


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Filling By Count

Figure 20.36 Slat counter


Filling By Count

3. Column Counters Products that have a constant thickness and flat

surfaces, such as cookies, tablets, or washers, canbe mounted by measuring the height of stacks ofthe product.

Single track machines with only one column may beused, or machines with two or more tracks may beused to gain extra speed.


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Filling By Count

4. Electronic Counters Use electric-eyes or other sensing devices

to detect the product item passing a givenpoint.

Can count objects of a wide variety of sizesand shapes with only minor change-overprocedures.


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