Basic Guide to Liquid Filling. A Filamatic White Paper on the basics of liquid filling including filling techniques, metering systems, and nozzles

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Jeffry Dickerson
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1 A Filamatic White Paper on the basics of liquid filling including filling techniques, metering systems, and nozzles

2 When beginning your liquid filling equipment search, it is important to consider the different aspects of your product (or application) and the demands of your project. There are four characteristics that will help in determining the type of filling machine you will need: the liquid s nature or characteristics, fill volume(s), production rate(s), and container description(s). Nature of the Product The first question that you will need to answer about the nature of a product is the product s viscosity. You can describe the viscosity by using the terms water-thin, semi-viscous, or viscous. Those products that are free-flowing, or have a consistency of water, would be considered water-thin opposed to thick substances such as hair gel, oils, and pastes that are considered viscous. Below is a chart with some examples of products and their viscosity. Type of Liquid Centipoise (cp) Viscosity Tomato Paste 190,000 Viscous Petroleum Jelly 64,000 Viscous Ink (paste) 45,000 Viscous Oil-SAE 140 2,200 Viscous Shampoo 800-1,000 Viscous Hand/Body Lotion 700 Semi-Viscous Plastisol 700 Semi-Viscous Oil-SAE Semi-Viscous Spar Varnish 420 Semi-Viscous Soybean Oil 160 Semi-Viscous Maple Syrup 144 Semi-Viscous Oil-SAE Semi-Viscous Corn Oil 72 Semi-Viscous Liquid Ink 25 Water-Thin/Free Flowing Colognes/Perfumes 1-7 Water-Thin/Free Flowing Water 1 Water-Thin/Free Flowing Sulphuric Acid 0.2 Water-Thin/Free Flowing Filling Techniques The product s nature will determine the correct pump to use in your filling machine as well as the filling technique that should be used. For example, does your product tend to be foamy? Does it contain particulate matter? Does it contain an ingredient (such as alcohol or acetone) that is flammable? The different characteristics of products require different filling techniques. Bottom-Up Filling: Used for foamy products, or to reduce splashing, nozzles are lowered to the bottom of the container before filling and then rise just above the liquid as the container is being filled. 2

Locate Filling: Used for non-foamy products; nozzles are located into the neck of the container, fill, and then pulled out.

Static Filling: This filling technique is typically used for filling machines with no nozzle movement.

second half of the fill it can do so. Flammable/Hazardous Material Filling: Any product that is flammable or hazardous (i.e. defined as those liquids with a flashpoint of 100 F or less) needs to be filled using an intrinsically-safe machine.

electricity required), to assure that the filling process is safe for those working nearby.

Some products such as sauces, condiments, and food ingredients may need to maintain an elevated temperature during the filling

mascara use the hot fill technique since the product is either too thick or a solid at room temperature, and therefore, unable

Metering Systems (Pumps) & Nozzles There are additional filling system components that are affected by the nature of the product.

that your project requires, the optimum metering system could be a Piston, Peristaltic, Flow Meter, Lobe Pump, or Gear Pump.

3 Locate Filling: Used for non-foamy products; nozzles are located into the neck of the container, fill, and then pulled out. Higher production rates can typically be achieved using this method. Static Filling: This filling technique is typically used for filling machines with no nozzle movement. Many semi-automatic filling machines use this type of filling. Profile Filling: Using servo-motor technology allows you to vary the speed of the filling process inside the container. For instance, if your product requires you to fill at a fast speed for the first half of the fill and then slow down for the second half of the fill it can do so. Flammable/Hazardous Material Filling: Any product that is flammable or hazardous (i.e. defined as those liquids with a flashpoint of 100 F or less) needs to be filled using an intrinsically-safe machine. Intrinsically-safe machines are built with a remote, intrinsically safe control system or are completely air operated (no electricity required), to assure that the filling process is safe for those working nearby. Hot Fill: This technique is used with products that must be heated and filled at elevated temperatures. Some products such as sauces, condiments, and food ingredients may need to maintain an elevated temperature during the filling process in order to assure a sanitary environment of the closed container; others like deodorants, candles, lipstick, and mascara use the hot fill technique since the product is either too thick or a solid at room temperature, and therefore, unable to flow through the pumps. Metering Systems (Pumps) & Nozzles There are additional filling system components that are affected by the nature of the product. Selecting the metering system is one of the most significant pieces. Depending upon the accuracy, viscosity, fill volume, etc. that your project requires, the optimum metering system could be a Piston, Peristaltic, Flow Meter, Lobe Pump, or Gear Pump. The product contact parts of the metering system are typically constructed of stainless steel. Non-metallic materials are used for products that are not compatible with stainless steel. FUS Piston FKS Piston FSV Piston KYU Piston DUS Piston Peristaltic Flow Meter Rotary Lobe Rotary Gear * These pictures represent the inside of the metering system and how it works. 3

4 A nozzle is a device that is designed to control the fluid flow as it exits the metering system and enters the container. They are available in a variety of types to provide drip-free, foam-free, and string-free fills with your product. Stainless steel and non-metallic materials of construction are most common. Standard Nozzle: used with a majority of liquid products. Standard Nozzle with Built-in Check Valve: prevents dripping when filling low surface tension liquids. Screens inserted into the nozzle tip may also be incorporated to eliminate dripping. Valve-In-Tip Nozzles: provide positive cutoff for drip-free, string-free filling. This nozzle is actuated by air pressure and used with foamy or non-foamy liquids. The valve-in-tip nozzle may be required when the filling application requires the use of lobe pumps, gear pumps, or flow meters. Fill Volume and Container Description The nature of the container also has an impact on certain elements of the filling machine that you will need. The more information you can give about the container the better, such as: Is it made of glass, plastic, etc? What is the shape of the container? Is it stable when placed on a moving conveyor? What is the fill volume? (Give the minimum and maximum volumes) What is the size of the container? (Give dimensions or drawings if possible) What is the size of the opening of the container? What type of closure will be used: screw cap, pump/spray, rubber stopper? Production Rate The production rate is a key factor in deciding what type of machine you will be using. There are two main classifications of filling machines: automatic and semi-automatic. Semi-Automatic Liquid Filling Machines (or Benchtop Filler) A semi-automatic liquid filling machine, or Benchtop Filler, is a more portable machine that needs some assistance in operation. They are a cost effective solution for start-up companies or ideal for small production runs, R & D departments and testing labs. A Benchtop is equipped with either a single or dual station filling system and can typically fill up to 50 containers per minute depending upon the product, fill volume, and dexterity of the operator. They also have a modular design with built in expansion capability for production changes and are easy to set-up, operate, clean, and changeover. 4

Semi-Automatic Benchtops Automatic Liquid Filling Systems An automatic filling system can range from a filler only to an integrated machine,

Automatic filling systems have a conveyor that moves the container to the filling system without the need for manual placement of the container

The production rates will be higher with an automatic filling system, and the cost will be higher than a semi-automatic machine.

fashion where the containers are constantly moving, typically providing a faster production rate than a comparable intermittent motion system.

In-Case, Cubitainer as well as the ability to integrate OEM systems with the filler.

5 Semi-Automatic Benchtops Automatic Liquid Filling Systems An automatic filling system can range from a filler only to an integrated machine, typically referred to as a Monobloc, that performs many packaging functions. Automatic filling systems have a conveyor that moves the container to the filling system without the need for manual placement of the container under the fill nozzle. The production rates will be higher with an automatic filling system, and the cost will be higher than a semi-automatic machine. Containers can be filled in an Intermittent Motion fashion where the container is stationary during the filling process or in a Continuous Motion fashion where the containers are constantly moving, typically providing a faster production rate than a comparable intermittent motion system. Depending upon your application and project needs, there are also different types of automatic liquid filling systems such as Inline, Monobloc, In-Case, Cubitainer as well as the ability to integrate OEM systems with the filler. Inline Fillers provide a linear path for the container whereas Monoblocs typically incorporate intermittent-motion turret indexing systems. Inline Filler Monobloc Filling System In-Case Filling Systems typically use a continuous motion filling process to fill containers that are already loaded into cases and the Cubitainer Filler is designed specifically to fill Cubitainer bladders positioned within the associated cartons. 5

In-Case Filling Line Cubitainer Filling Line For a fully integrated system, you are able to integrate OEM

closing/sealing systems, Strapping systems, Palletizers, Coding systems, Tamper Evident Banding, Puck

systems, or Case packing/loading systems.

6 In-Case Filling Line Cubitainer Filling Line For a fully integrated system, you are able to integrate OEM systems such as Bulk container unscrambling systems, Labelers, Induction sealers, Case Erectors, Case closing/sealing systems, Strapping systems, Palletizers, Coding systems, Tamper Evident Banding, Puck loading/unloading systems, Cappers, Container cleaning/rinsing systems, Checkweigher, Carton loading systems, or Case packing/loading systems. An integrated system is a turnkey, single source solution for a project that has many steps or packaging requirements. Fully Integrated Packaging Systems Once sufficient information about the nature of the products, fill volumes, container descriptions, and production rates is provided, the process of determining the best filling equipment for your application can move forward quickly. 6

7 About Filamatic Filamatic, a division of National Instrument, LLC, manufactures liquid filling equipment and integrated liquid packaging systems. They have been serving the pharmaceutical, biotech, healthcare, cosmetic, chemical specialty and food industries since 1950 and have thousands of liquid filling machines in operation around the world. For more information visit their website at or contact info@filamatic.com or

SVF Series CCUTEK. Key Features: Options: SVF Semi-Automatic Piston Filling Machines

SVF Series CCUTEK. Key Features: Options: SVF Semi-Automatic Piston Filling Machines SVF Series Semi-Automatic Piston Filling Machines Key Features: Single head filler configuration (8-128 oz. cylinder) Multi-stroke operations (Multiple doses per container) Pneumatic operation Direct from