Presented By

Safder Ali BhattiSr. Production Officer

ral Liquid section

Working on syrup filling machines

Introduction

Considerations in selecting a filler

Basics of liquid filling technologies

Types of filler Compact Line syrup Filling machine

Contents

Introduction

Technologies & capacities

Filling machine capacities

Expensive technologies

Heart of filling line

Line capacity

Technological innovations

Introduction

What a filler can be asked to do???????

Introduction

Considerations in selecting a filler ?????

Types of product to be fill…..???

Viscosity of liquidPaste or solidStable or unstableVolatile or non volatileExplosive or notHot or frozen

Considerations in selecting a filler

Size , shape , and construction of container in which product is to be filled…..???

Large size or small size container (jar) usedGlass bottles or plastic bottles or metal

cansShape Neck size

Considerations in selecting a filler

Way the product is measured to be filled…..???

By volumetric methodBy weight methodBy level controlled filling

Considerations in selecting a filler

Desired speed of the operation…..???

Relatively slow manual operationSemiautomaticFully automatic

Considerations in selecting a filler

Special handling requirements of the product…..???

Cost of installation…...???

Considerations in selecting a filler

Basics of liquid filling technologies

Liquid Volumetric Filling1. Dosing filling

Measure Cup filler Piston filler

2. Level controlled filling Gravity filling Vacuum filling Gravity vacuum filling

3. Time controlled filling

Weight fillers

Basics of liquid filling technologies

Types Of Fillers

1. Over Flow Liquid Filler2. Servo Pump Liquid Filler3. Peristaltic Liquid Filler4. Time Gravity Liquid Filler5. Piston Liquid filler

Types of filler

This type of filler is perhaps the most widely used machine in small bottle filling operations because it handles a wide range of thin, free flowing liquids as well as liquids with medium viscosity.

Over Flow Liquid Filler

The supply side (dark blue) of a two part nozzle is used to pump product into the container.

How does it works?

When the container fills up to the target fill height, the excess product and foam is forced out of the container (red arrows) via the return side to the original product source tank.

Advantages

Overflow Filler Selection Guide

High performance,Easy to clean,Easy to operate,Expandable at low cost,Offers greatest flexibility at lowest cost.

Examples

Sauces,Syrups,Light gels and shampoos,Foamy cleansers and chemicals,Water and other non carbonated aqueous beverages.

Application:This type of filler is best suited for

liquids with low to medium viscosity. liquids with solid particulates not exceeding 1/16" can also be filled. Note that overflow fillers are the machine of choice in handling very foamy products at higher speeds.

This is a very versatile filling machine capable of filling nearly any type of product that can be pumped. Each nozzle has a dedicated servo controlled pump that can deliver thin liquids, medium and thick viscosity liquids, and liquids with large particulates.

Servo Pump Liquid Filler

The filler's master computer independently tracks the rotation of each pump head so that it knows precisely how much product has been delivered.

How does it works?

When the target fill volume is reached, each pump and nozzle is instantly shut off,  resulting in high accuracy fills of your valuable products. The computer stores all fill parameters in memory for fast changeovers.

Advantages

Servo Positive Displacement Filler Selection Guide

computer control & Operator setup is greatly simplified. The design also lends itself very well to sanitary applications due to the ease of automatic cleaning.

• Examples

The servo filler is found in all industries from pharmaceutical, cosmetic, dairy, chemical, food, etc. Both thin and thick products, and also very large particulates can all be filled on this machine. Cosmetic creams as well as thick, chunky sauces at pasteurized temperatures can all be filled.

Application:It is extremely flexible and designed to fill almost any product in any fill volume. Even 55 gallon drums can be filled.

This filler is the machine of choice for high value; small volume fills at very high accuracy. It is primarily suitable for aqueous and other light viscosity products.

Peristaltic liquid filler

The peristaltic pump makes intermittent contact on only the outside of the surgical (product) tubing so that the product only touches the inside of the tubing. The filler's master computer independently tracks the # of rotations of the peristaltic pump head so that it knows precisely how much product has been delivered. When the target fill

volume is reached, the pump stops and the remaining product fluid does not drip out due to pipette action. The computer stores all fill parameters in memory for fast changeovers.

Advantages

Fluid path is disposable; easy cleanup and elimination of cross contamination problems. Accuracies of 0.5% are achievable for fill volumes less than 1 ml.

• Examples Pharmaceutical preparations, fragrances, essential oils, reagents, inks, dyes, and specialty chemicals.

Application:Specifically designed for high value, small volume fills at very high accuracy. Suitable for aqueous and other light viscosity products.

This is the most economical type of filling machine for a limited range of applications. This filler is best suited for liquids with very thin viscosities that do not change with ambient temperature or with batch variation.

Time Gravity liquid filler

The product bulk supply is pumped into a holding tank above a set of pneumatically operated valves. Each valve is independently timed by the filler's master computer so that precise amounts of liquid will flow by gravity into the container. Gravity fillers

built with bottom up fill capability can handle a wide range of flow able liquids including foamy products.

• Advantages

This is the most economical type of filling machine for a limited range of applications. It is especially well suited for corrosive chemicals.

• Examples

Water, solvents, alcohol, specialty chemicals, paint, inks, corrosive chemicals i.e. acids and bleach.

This type of filler is best suited for liquids with very thin viscosities that do not change with ambient temperature or with batch variation. Although this type of filler is used predominantly on products that do not foam.

• Application:

The piston filler is one of the oldest and most reliable types of fillers used in the packaging industry. This filling machine is best suited for viscous products that are paste, semi paste, or chunky with large particulates.

Piston liquid filler

The piston is drawn back in its cylinder so that the product is sucked into the cylinder. A rotary valve then changes position so that the product is then pushed out of the nozzle instead of back into the hopper.

How does it Work?

Piston Filler Selection Guide

• AdvantagesThis lower cost conventional technology is easy to understand for most users. Fast fill rates are achievable with fairly thick products. Warning: this technology is nearly obsolete with the advent of servo positive displacement fillers.

• Examples Heavy sauces,cosmetic creams, heavy shampoo, gels, and conditioners, paste cleaners and waxes, adhesives, heavy oils and lubricants.

These piston fillers are built to meet food grade standards and can also handle various chemical applications.

• Application:

Compact Line Syrup Filling Machine

Major units of machine{filler , sealer, & labeler unit}Capacity {24 to 250 bottles per minute}Operation {fully automatic, computerized base(P.L.C)}Filling UnitType of filler used {piston filler & servo pump filler}Use of sensors for automatic controlNumber of filling nozzles…???Sealing UnitNumber of sealing heads…???Importance of adjustments of sealing head’s blades &

springsImportance of lubrication of sealer heads

Compact Line Syrup Filling Machine

Labeler UnitLabeler MagazineLabeler pinsLabeler clipsLabeler rollerLabeler bottle guide trackS.S Gum Container with pneumatic Pump

Compact Line Syrup Filling Machine

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