Selection Criteria for Liquid Filling Machines

First Tell us this ! : Liquid Type , Bottle Type , Your Manpower , Desired Output

LIQUID TYPE :

1. Flow : Like Water , OR Syrup , OR Honey
2. Is it sticky ?
3. Does it contain particals while filling
4. Is it Hot or Cold (Ambient Temperature)
5. Does it form foam while filling:
6. Product is seasonal or All season?

Other Details Like

1. Bottle Material : HDPE , Glass , PET - what ?
2. Fill Sizes : 100 ml , 150 ml etc
3. Output per size per day : eg 100 ml 2000 Bottles per day ( If you are beginner & starting new , give us appx projections - fine.
4. Want a Non-touch Process ?
5. Type of Labour available : Skilled / Unskilled ?
6. Manpower : Plenty/ few ?
7. Reqt for new project / existing ; when needing the m/cs ?

Induction Cap Sealing Machines

Usually to keep the bottle leak-proof , Plugs are inserted into the bottle neck , very popularly known as " Inners". These inners are press-fitted. Still after some days some gases leak out from these inners. Hence to seal them air tight , they are sealed by "Heat Seling Machines" These are table top machines with thermostat controlled heaters , which seal the inners to the bottle necks. After this the bottles are capped by capping machines.

To avoid this plugs , plugging & heat sealing , nowadays induction cap sealing machines are used. Here the cap comes with a Wad inserted. After Bottle filling , Cap is applied (With the Wad) and then the bottle passes below the induction cap sealer. It is automatically sealed.Three types of m/cs are available :
1. Hand Held 2. Semi Automatic & 3. Automatic also.

Capping Machines

Bottle Caps are available in various types. Some are called as ROPP (Roll On Pilfer Proof) , these are aluminium PP Caps , very commonly used for Medicine syrup glass or PET Bottles.

To seal the bottle with caps , diff m/cs are available .

Hand Optd M/cs : All Operations done manually. Bottle placement , cap placement , Cap lever operating etc.

Semi Auto M/cs : Caps are placed manually , Foot pedal or a Pneumatic ram raises / lowers the bottle. Capping is done by a rotating die , by electric motor. In ROPP , threading and sealing is done like this.

Automatic Machines : Bottles are fed by conveyor , Caps are fed by Cap Feeders , Located at positions to apply Capping mechanism to seal thye Bottles.

Vacuum Filling Machine

This Method is also used for several products.

The machine consists of a vacuum pump which initially evacuates the bottle to be filled , when connected. Then the created vacuum is filled by the liquid to be filled. Upto a certain predetermined level , it is filled. The surplus liquid travels to the Overflow Jar. Once this is full , the drain valve is opened & liquid is removed.

This machine is very easy to operate , very convenient to use.

The limitation is that it can fill only Glass Bottles.

Very popular for Flavoured Milk , Tomato Sauce , Liquor , Wine etc.

Bottle Washing

BOTTLE WAHING MACHINERY
Before Filling : This is the Reqd Operation. Following are the machines for Bottle Washing :

1. Brush Type Machines : They are used for Seconds OR Used Glass bottles to clen from inside. Usually consist of a tank in which bottles are soaked in soap water , brushed & rinsed by fresh water by jets.

2. Rinsing type machines : Here bottles are rinsed from inside with a water jet , they pass through the chamber in inverted condition & get rinsed.

3. Auto Rinse Fill Capping Machines : On these machines , bottle Rinsing , Filling , Capping all operations are done autonatically

More popular models are : Brush Type M/c , Rotary type Machine & Rinse-Fill-Cap M/c.

Liquid Mixing

LIQUID MIXING & PREPARATION

Every product has its unique composition. Various ingradients are mixed together and a chemical reaction is formed , by Mixing together.

Various types of Mixers are available :

1. High Speed Stirrers : These have an electrical motor directly coupled to a central shaft which has blades. This stirrer is usually stand mounted & can be inserted into the storage/preparation tank seperately when mixing.

Typical application : Dilution , Mixing liquid-liquid thin types. Essenses , Chemicals , Dyes etc.


2. Slow Speed Stirrers : Usually these stirrers have an Electrical Motor coupled to a gearbox , mounted directly on the vessel/tank , vertically. These are slow speed , but with added power (torque) of a gearbox.

Typical Application : Formulation , Mixing of syrups , Thick formulations mixing etc.

3. Homogenisers / Emulsifiers : These are vertically hung type mixers , typically used to mix homogeneous suspensions , creams etc. They shear the product for partical size reduction. Driven by top coupled motor , Mounted on a height adjustable stand.

Typical Applications : Suspensions , Creams , Syrups etc.

Bottle Filling - Piston Filler - Volumetric type

Bottle Filling - Pressure type (Piston)

The liquid to be filled in is sucked from the below placed container, and exact volume is dispensed in the bottle as per the setting. The Volume set is the length of piston travel inside the cylinder (Syringe).

In Mechanical Models , the volume is set by setting screw & in pneumatic models , either by legth settrs or through digital key pad.

The Digital Key pad machine is tremendously beneficial since it sets the correct filling volume. For more details please consult

The models available are : upto 260 ml , 1000 ml etc. Method can be Semi OR Fully automatic.

Liquid Filtertion

Filteration

Many kind of filters & machines are available. Mostly the cartridge type filters , bag filters are most popular. For finemost filteration , Membrane technology is used.

For Users in Pharma , Ayurvedic , Herbal Lines - Sparkler type Hoz Filter Presses are very popular. Here the liquid from storage tanks is pumped to the main cartridge assembly which consists of a series of plates with wiremesh and filter cloth. The filtered liquid comes out tho' the outlet.

The Filters are selected by the Flow Rate desired. , Also the Cake : The left-Out is very important.

Material of Construction is usually Stainless Steel for all Hygeinic applications.

Liquid Storage :- The First Consideration

LIQUID STORAGE.

Liquids are usually stored in Storage tanks.

Selection

Construction: Storage can be Round or Square or any other shape also. Normally Round are more popular. The designs are selected as 2:1 i.e. if Height is 2 Ft , Dia will be 1 Ft and so on. Ideally they should be used with caster wheels for mobility purpose.

Size : has to be in volumetric litres , some space say 10 % should be left for overflow etc. Say 100 Ltrs , 500 ltrs etc.

Material of Construction : For Pharma , Food & other health related or Corrossion inhibited industrial applications it should be Stainless Steel , Otherwise any matl.

Special Modules : Some tanks can be provided with jackets also , where the liquid inside can be heated if reqd with electrical heating system. Special Stirrers are also available for this.