For anyone new to the packaging industry, purchasing equipment for a project can be an intimidating process. Whether looking at a complete line or an individual machine - from power conveyors to liquid fillers, capping machines and labelers - there are a number of questions that should be asked before choosing a packaging machine. In the next few weeks, we will outline some general questions that can help guide the inexperienced packager in selecting the right packaging equipment for his or her needs, starting with liquid filling machines.
Filling machines are the one piece of packaging equipment that will interact directly with the product being packaged. While more than one filler may work to get any specific product from a tank to the bottles or containers, for any given project there will usually exist one filling machine that will provide the best solution given the details of the packaging project. That solution can often be identified by asking some or all of the questions below.
Filling machines can use a variety of principles to move product from a holding tank to the bottles or containers waiting to be filled. Each principle offers some unique benefit to the packaging process. This question can begin to be answered by looking at the product itself. Thin, free-flowing products are usually filled using an overflow filler or gravity filling machine. Thicker, more viscous products will normally require a piston filler or pump filling machine. These are general rules and, of course, exceptions do exist. For example, when a packaging project includes multiple products with a wide range of viscosities, a pump or piston filler may be used with both thick and thin products.
The product is not the only consideration when it comes to choosing the correct filling machinery for a given project. The filling machine must also work with the varying sizes of bottles or containers being used for packaging the product. Many filling projects will include more than one bottle size. In fact the bottles may range from a few ounces for travel or sample size products to a gallon or more for bulk containers. Different packaging machines will require different changeover for the bottle sizes. While each machine will be able to handle a range of containers, as that range expands, some liquid fillers will work better than others for quick, efficient changeover and less filler downtime. Changeover time leads to downtime, which in turn can effect total production rates.
A third consideration when choosing a filling machine is the production rates that can be achieved. The initial assessment of production rates can be achieved through simple math. For example, if a liquid filler is manufactured with eight fill heads and can complete 4 fill cycles per minutes, the machine will fill thirty-two bottles per minute, about 1,900 bottle per hour or approximately 15,000 bottles in an eight hour shift. Adjustments, such as adding fill heads or speeding up pumps, can be made to try to increase the production rates. In the end, ensuring that the necessary number of bottles will be filled each day is a fairly simple task. However, most companies that are packaging a product hope for, and expect, growth in the future. The expected growth can make the analysis a little more difficult.
Figuring production rates for the present is fairly simple, but trying to estimate growth and ensuring that a filling machine can handle increased production in the future is a little more difficult. Packagers should make sure that the filling machine chosen has the ability to grow with the company. Many liquid fillers are upgradeable in more than one way. Some packagers may start with a semi-automatic filler that will allow for the addition of a PLC and indexing system (and therefore automatic production) in the future. Even automatic filling machines can be upgraded to add additional fill heads in the future. Furthermore, the packager can plan ahead by purchasing a machine capable of meeting production demands on a single shift. When growth occurs, additional shifts can be added to meet the demand. In general, a packaging company should simply ensure that the machine they are purchasing is not set on their production floor already meeting it maximum potential for output of product.
Not all packagers will automate every aspect of a packaging system at one time. Once the filling machine has been chosen, ensure that the equipment will integrate with existing packaging equipment or with equipment to be purchased in the future. Many automatic liquid fillers will be manufactured to roll up to any existing power conveyor and begin filling bottles. However, semi-automatic or custom filling equipment may not be as versatile. Ensure that the machine chosen from the factors considered above has the ability to work well with other packaging equipment to again avoid leaving the company with obsolete machinery should change occur in the future.
Of course, no two filling projects are the same, and each individual project will bring with it additional questions and concerns. Some projects may require filling of a hazardous product or even filling within a hazardous environment. Other projects may have special electrical requirements or the need to do away with electricity completely. Other products may require sanitary filling machines to guard against product contamination. Answering the general questions above will help to ensure the most economical and efficient filling machine is chosen for a specific project, but the machine manufacturer should work with the packager to be certain that project specific questions, along with the general questions, are all answered before the filling machine is manufactured.
All you want to do is buy the right liquid filling system. But no, nothing can be easy or straightforward nowadays&#; can it? So whatever industry you&#;re coming from, we know there are a lot of things to consider when trying to find the best solution for your needs. Today, we are going to briefly discuss the &#;5 Things You Must Know&#; when looking your liquid filling machine.
One of the more important things to consider when choosing your liquid filling machine is your fill rate. How much do you want to fill per minute, per hour, per day and overall per month?
This is an important area of determination since it will also help in identifying the right level of automation for your needs. That is, filling a 5-gallon container vs a precision vial fill application is probably going to require a different type of filling solution. These types of details will also help with determining your setup options as it relates to your metering system, aka liquid filling pumps.
Sounds simple enough&#; what type of liquid product do you have?
Being able to clearly describe your liquid product as very viscous, semi-viscous, or a very fluid, water-like product, will go a long way in helping to match your production needs with the best solution.
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Your type of liquid product may also require a specific environment. A level of cleanliness, or even system design may be something that needs to be taken into consideration; especially, when you are dealing with pharmaceutical, diagnostic and biotech environments. Aseptic filling, which means the product needs to be filled within a sterile environment, vs non-aseptic filling, so those basic, but very important details should be noted within your overall application.
When dealing with specialty chemicals, you may also have to consider if the product is flammable and requires an explosion-proof filling system. There are certainly stringent rules and regulations regarding how these types of flammable liquids need to be handled in a manufacturing and production environment.
When dealing with liquid filling applications, what you put your liquid product into is just as important as the product itself.
There is a world of different bottle shapes, sizes, and types of associated caps as it relates to closing/capping requirements. You can muddy the waters even more, if you will, should your container require a fill stopper crimp cap, fill cap, press on cap, twist on, spray bottles, or even an atomizer spray &#; all completely doable, but certainly needs planning ahead and constant dialogue amongst the project team members. Liquid packaging can have a vast array of possible and creative solutions, but also pitfalls, if unaware.
Another part of the container aspect is understanding any labeling requirements. How difficult or easy is it to label your container&#;s surface? Also, what type of labeling solution do you want &#; a fully-automated, integrated labeler, or a standalone system? You can certainly incorporate whichever solution you prefer, but uncovering these needs ahead of time will ultimately save you time and money as you complete your project. If you&#;re seeing a theme, you are clearly ahead of the game&#; constant communication and planning ahead will always serve you well.
If you&#;ve already answered your initial question, &#;Q#1: What is your desired fill rate&#;, you&#;ve already taken a big step in determining what level of automation is best for your application.
For example, if you are filling about 5,000 bottles a day, or roughly 10-12 containers per minute, a Benchtop solution may best fit your needs. Whether a single or dual nozzle, a handheld semi-automatic Benchtop filling machine could be an excellent solution for your needs &#; an affordable, quality and workhorse solution.
Now let&#;s say your production requirements have you filling about 25,000 bottles per day, or roughly 50-52 containers per minute. Here, you may want to increase your production throughput by considering a slightly higher level of automation with an intermediate inline filling system, or even a higher output scenario with a larger Monobloc design. Of course, as you increase your levels of automaton, there are certain costs associated with those greater mechanical and electrical elements
Going back to your specific filling requirements, these different levels of automation may/may not make sense. Therefore, it&#;s important for your project team to be on the same page as it relates to your liquid filling application.
Often overlooked until the later moments, another important aspect to consider when choosing a liquid filling system is your available floor space. You must accurately know your available clean room, laboratory or facility floor space. A bad scenario&#; you purchase an expensive production line that does not fit into your clean room or overall floor space &#; not good.
When determining your floor space, or the required footprint of your liquid filling machine, be sure to also factor in your human element as well. That is, your operators as well as any necessary space for inventory and supplies.
Of course, there are many other details to consider when looking for the right liquid filling solution for your needs. Just to name a few, lead times, available budgets, as well as specific industry requirements like fill accuracies may also help determine what type of liquid filling solution is right for you.
The best thing to do is not go on this journey alone. Do your homework, research a few companies, talk with their representatives, share relevant, appropriate details regarding your application, and be sure to prepare and understand the &#;5 Things You Must Know&#; when choosing your liquid filling system. For more information on liquid filling, capping and labeling solutions, please or call 866.258.. Visit www.filamatic.com
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