A Deep Dive into Liquid Filling Machine Working Principle

- Thursday, November 16,

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Liquid products are ubiquitous in our daily lives, but have you ever considered how liquids are filled into various containers? This is where a liquid filling machine becomes essential. These machines provide stability, safety, and hygiene for liquid products efficiently, making them highly popular in the pharmaceutical, cosmetic, and food industries.

After reading this blog, you will gain a comprehensive understanding of liquid bottle filling machines, including their working principle, standard operating procedures, and common faults that may arise.

Let's begin by defining what a liquid filling machine is before exploring its operational mechanics.

What Is A Liquid Filling Machine?

As the name implies, a liquid filling machine is a device designed for packaging liquid products. These machines are utilized across various industries, including food and beverage, pharmaceuticals, chemicals, and cosmetics.

In the pharmaceutical sector, for instance, a liquid filling machine can package eye drops, oral liquids, syrups, and disinfectants. Thus, reliability in terms of hygiene and quality is crucial.

Liquid Filling Machine Working Principle

To accommodate different production scales, various types of liquid filling machines are available on the market, including automatic, semi-automatic, and manual liquid filling machines.

Regardless of type, all of these machines operate on the same fundamental principle: they pump liquid from a reservoir into containers. The volume of liquid dispensed is controlled by several factors, such as container size, liquid viscosity, and desired filling volume.

Now, let’s delve into how these three different types of liquid filling machines operate.

How Does A Manual Liquid Filling Machine Work?

A manual liquid filling machine is a versatile device used in the pharmaceutical, cosmetic, and food industries. Unlike automated systems, it does not require automation, making it ideal for small businesses or laboratory applications. Below is the working principle of a manual liquid filling machine:

Step 1: Pouring the Liquid

After setting the filling capacity of the machine, pour the liquid into the feed hopper.

Step 2: Filling the Bottle

Position the bottle under the discharge nozzle with one hand while slowly pressing the handle with the other hand to allow the liquid to flow out.

How Does A Semi-Automatic Liquid Filling Machine Work?

A semi-automatic liquid filling machine combines manual and automatic operations. Typically, it includes an automatic filling unit, but it requires human intervention to load containers and operate the filling process. Here is a breakdown of its working principles:

Step 1: Connecting the Air Supply

Connect the air inlet tube to the air supply and turn on the air power switch. Pulling out the air switch will close it. You can also adjust the air pressure by manipulating the filter’s top part.

Step 2: Adjusting the Filling Speed

Turn the speed adjustment valve and the filling interval adjustment valve to set the appropriate pumping speed, preventing liquid from rushing out during filling.

Step 3: Determining the Filling Volume

Adjust the magnetic switch position using the hand wheel on the machine's right side to set the required filling volume. Lock the movable electromagnetic switch on the cylinder to start the filling process.

How Does An Automatic Liquid Filling Machine Work?

The automatic liquid filling machine is characterized by accuracy, efficiency, and consistency. It operates on the principle of volumetric filling, meaning it fills each container with a predetermined volume of liquid, making it suitable for mass production in beverages, pharmaceuticals, chemicals, and other industries. Here’s how it functions:

Step 1: Setting Parameters

Begin by setting all parameters according to the liquid's nature and viscosity, including machine speed, temperature, and pressure.

Step 2: Loading Bottles

Place the bottles in the feed hopper. As the rollers rotate, the bottles are conveyed one by one onto the conveyor belt, which transports them for further processing.

Step 3: Conveying the Bottles

The conveyor belt is integral to the entire operation of the liquid filling machine. It adjusts the spacing of the bottle stoppers based on bottle diameters to ensure smooth transportation.

Step 4: Completing the Filling Process

The filled bottles reach the filling unit, where the mechanism accurately injects the required liquid volume using a plunger or rotation valve.

Step 5: Capping the Bottles

Finally, the filled bottles move to the capping area, where they are securely capped and readied for further packaging and labeling.

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Standard Operating Procedure For Liquid Filling Machine

Fully automatic liquid filling machines are more sophisticated than manual and semi-automatic ones. Their complex mechanisms require appropriate expertise and training. Now that you understand how a liquid filling machine operates, the following Standard Operating Procedure (SOP) will guide you to use this machine safely and effectively and enhance production efficiency and quality.

Objective: Utilize an automatic liquid filling machine to achieve efficient and precise filling results.

Scope: This SOP outlines the step-by-step procedure for operating an automatic liquid filling machine.

Device and Materials:

• Automatic liquid filling machine
• Liquid to be filled
• Packaging containers
• Necessary safety equipment (gloves, safety goggles, etc.)

Procedure:

Preparation:

• Ensure that the liquid filling machine is operational and ready to use.
• Confirm that the empty bottles are clean and meet the machine's requirements.
• Prepare the liquid and measure the required filling volume.

Startup:

• Turn on the power as instructed.
• Verify that all necessary safety devices are in place.

Bottle Loading:

Load the bottles into the feed hopper, taking care not to exceed the machine's loading capacity.

Setting Parameters:

Adjust the filling speed, temperature, and air pressure on the machine's control panel.

Starting Filling Process:

Press the start button to commence the filling process, following the machine's operational program.

Monitoring:

• Watch for smooth movement of bottles on the conveyor belt. Prevent tipping or stoppage.
• Continuously monitor the filling process for issues like misaligned caps or malfunctioning cylinders.

Quality Check:

Regularly verify that the filling volume meets specifications and adjust as necessary.

Turn Off The Machine:

• After filling, safely turn off the machine according to the manual.
• Clean residual liquid and dispose of waste materials properly.

Cleaning And Maintenance:

• Use appropriate cleaning agents and refer to the user manual for maintaining all components.
• Schedule regular maintenance as outlined in the user manual.

Logging:

Document the filling process, including lot number, quantity filled, operator name, and any identified issues.

Note:

Consistently adhere to operating instructions and safety precautions, seeking guidance from certified technicians for technical inquiries.

Reference:

• Automatic liquid filler user manual
• Relevant safety regulations and instructions

Common Faults Of Automatic Liquid Filling Machine

Automatic liquid filling machines are complex and can experience faults. Fortunately, many issues can be easily troubleshot. Below are common liquid filling machine faults and corresponding troubleshooting tips:

Fault

Troubleshooting

Cylinder does not work

Check for proper air pressure, air hose leaks, and cylinder components.

Poor bottle transport

Adjust the spacing and tension of the conveyor belt.

Filling head misalignment with the bottle opening

Adjust the spacing and height of the filling needle.

Vibration during operation

Check if chain fasteners are loose.

Incorrect filling volume

Inspect for worn silicone seals, leaking one-way valves, and loose tubing connections.

Inaccurate capping

Ensure the bottle's center aligns with the gland opening and that air pressure is normal.

The Bottom Line

Liquid filling machines are crucial in the pharmaceutical industry. Understanding how liquid bottle filling machines work can enhance your medicinal packaging productivity and elevate your pharmaceutical business.