This document discusses considerations for selecting liquid filling technologies. It describes types of fillers like overflow, servo pump, peristaltic, time gravity, and piston fillers. It focuses on compact line syrup filling machines, explaining their major units for filling, sealing, and labeling bottles at automated speeds up to 250 bottles per minute. Key aspects like filler type, sensors, number of nozzles and heads, and adjustments are covered.

1. Presented By
Safder Ali Bhatti
Sr. Production Officer
ral Liquid section

2.  Introduction
 Considerations in selecting a filler
 Basics of liquid filling technologies
 Types of filler
 Compact Line syrup Filling machine

3. Introduction

4.  Technologies & capacities
 Filling machine capacities
 Expensive technologies
 Heart of filling line
 Line capacity
 Technological innovations

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

6. Considerations
in selecting a
filler ?????

7. Types of product to be fill…..???
Viscosity of liquid
Paste or solid
Stable or unstable
Volatile or non volatile
Explosive or not
Hot or frozen

8. Size , shape , and construction of container in which
product is to be filled…..???
 Large size or small size container (jar) used
 Glass bottles or plastic bottles or metal cans
 Shape
 Neck size

9. Way the product is measured to be filled…..???
 By volumetric method
 By weight method
 By level controlled filling

10. Desired speed of the operation…..???
 Relatively slow manual operation
 Semiautomatic
 Fully automatic

11.  Special handling requirements of the product…..???
 Cost of installation…...???

12. Basics of liquid
filling
technologies

13.  Liquid Volumetric Filling
1. Dosing filling
 Measure Cup filler
 Piston filler
2. Level controlled filling
 Gravity filling
 Vacuum filling
 Gravity vacuum filling
3. Time controlled filling
 Weight fillers

14. Types Of Fillers

15. 1. Over Flow Liquid Filler
2. Servo Pump Liquid Filler
3. Peristaltic Liquid Filler
4. Time Gravity Liquid Filler
5. Piston Liquid filler

16.  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.

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

18. High performance,
Easy to clean,
 Advantages Easy to operate,
Expandable at low cost,
Offers greatest flexibility at lowest cost.
Sauces,
Syrups,
 Examples Light gels and shampoos,
Foamy cleansers and chemicals,
Water and other non carbonated
aqueous beverages.

19. 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.

20.  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.

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

22. computer control & Operator setup is greatly
 Advantages simplified. The design also lends itself very well to
sanitary applications due to the ease of automatic
cleaning.
The servo filler is found in all industries from
pharmaceutical, cosmetic, dairy, chemical, food,
• Examples 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.

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

24.  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.

25.  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.

26. Fluid path is disposable; easy
cleanup and elimination of cross
 Advantages contamination problems.
Accuracies of 0.5% are achievable
for fill volumes less than 1 ml.
Pharmaceutical preparations,
• Examples fragrances, essential oils, reagents,
inks, dyes, and specialty chemicals.

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

28. 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.

29. 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.

30. This is the most economical type of
• Advantages filling machine for a limited range of
applications. It is especially well suited
for corrosive chemicals.
Water, solvents, alcohol,
• Examples specialty chemicals, paint, inks,
corrosive chemicals
i.e. acids and bleach.

31. 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.

32. 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.

33. 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.

34. This lower cost conventional technology is easy
• Advantages 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.
Heavy sauces,cosmetic creams, heavy shampoo,
• Examples gels, and conditioners,
paste cleaners and waxes, adhesives, heavy oils
and lubricants.

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

36. Compact Line Syrup Filling
Machine

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

38.  Labeler Unit
 Labeler Magazine
 Labeler pins
 Labeler clips
 Labeler roller
 Labeler bottle guide track
 S.S Gum Container with pneumatic Pump