4 Types of Filling Machines and Their Benefits For Your Line

If you are an individual considering operating a filling machine, you may have noticed there are a lot of options to choose from. There is a lot that goes into understanding the diverse range of types of fillers available in the market and their respective functionalities. This can often complicate the ability to make informed decisions about which type of filling machine would best suit the business's specific needs and operational requirements.

There are four main types of filling machines: automatic pump fillers, piston filling machines, gravity fillers, and overflow fillers. The purpose of filling machines is to accurately dispense products into containers using time, number, weight, volume, or a mix of these metrics. The choice of filling machine depends on the product being processed. These machines can be used to significantly increase production speed. The level of automation, whether manual, semi-automated, or fully automated, is determined by the product's timeline, as hand-filled products typically have a longer time to market and revenue generation. 

Automatic Pump Fillers and High-Volume Production

Automatic pump fillers are well-suited for higher-volume production. These filler machines work well with thicker products that need to be filled quickly.

Automatic Pump Fillers for Precision and High-Speed Production

Automatic pump filling machines offer precise filling accuracy with adjustable volumes. These machines come with advanced features and are equipped with recent technology. They also come with adjustable pump speeds on the automatic fillers, which can be adjusted electronically. They are available with 1 to 12 positive close-fill heads. Automatic pump filling machines also contain a stainless steel product reservoir that has an automatic level control.

Pump fillers can process all liquids. This includes even more watery ones like CBD and essential oils. However, these filling machines are especially well-suited for thicker products. This means they are highly compatible with various viscosities and container sizes. Additionally, these fillers also work very well in special situations that include sanitary, hazardous, flammable, and corrosive products and environments.

Some other features of automatic pump filling machines include pneumatic indexing gates, no bottle/no fill sensors, bottle back up sensors,  on/off and speed controls, front panel start, and emergency stop. They also include container counters, tool-free adjustments and have an easily upgradeable design. All of these tools allow for strong automation capabilities for high-speed production.

Best Industry Applications for Automatic Pump Fillers 

Because of their high compatibility, automatic pump fillers can be used across various industries. Some of these industries include cosmetics, pharmaceuticals, and the food and beverage industry. In the cosmetics industry, these machines can be used for lotions, shampoos, conditioners, serums, gels, and cosmetic creams. In the pharmaceutical industry, these machines are perfect for syrups, medications, and ointments. In the food and beverage industry, these machines are ideal for sauces, syrups, oils, and honey. Additionally, these machines can also be used for items such as car wax, molten products, and paste cleaners. 

Piston Filling Machines and Precise Filling Requirements

Piston filling machines operate by measuring a set volume. The piston then draws back and allows that precise measure of product from its supply system to go into the piston chamber. The liquid is then pushed out through the fill head into the individual container. Because these machines use a pre-measurable exact quantity of liquid by volume, they are an excellent choice for liquids that need to be packed in precise amounts or are too expensive to risk any waste due to excess filling. 

Piston Filling Machines for Adaptability and Accurate Volumetric Filling

Piston filling machines are equipped with accurate volumetric filling, along with adjustable stroke and speed. They work with a user-friendly, touch-screen HMI, incorporate a conveyor belt for speedy filling, and have sensors to alert you to missing bottles or downstream jams. Semi-automatic tabletop piston fillers can move as fast as filling up to 30 bpm. However, remember when looking at semi automatic vs automatic machines, semi-automatic filling machines still require some manual operation.

Piston fillers work with a variety of substances, from thin, watery liquids to heavier, high-viscosity substances like car wax. These fill machines can also process any liquid or semi-solid with particulates, like orange juice with pulp, creams, pastes, oils, or even chunky salsa. They can also be adapted to work with sanitary, hazardous, flammable, and corrosive products and environments. Piston fillers are also ideal for speeding up production lines. Automatic piston fillers are available with one to twelve fill heads for increased productivity. There is also the economy two-head automatic piston filler variation, which can be operated with a foot pedal or in auto mode.

Uses and Applications for Piston Filling Machines

Piston filling machines can be used throughout various industries. In the cosmetic industry, these machines are ideal for filling creams, gels, and serums. In the pharmaceutical sector, these machines are perfect for creams, ointments, and medications that need precise measurement. They can also be used for more industrial applications, such as oils, lubricants, and automotive fluids.

Gravity Fillers and Cost-Effective Liquid Filling

Gravity filler machines are filling machines equipped with a hopper placed above a set of nozzles. The nozzle is filled with the liquid, which is then opened at the valve and dispensed into the bottles as gravity draws out the product. This system works by shutting the valves at set times after a certain amount of product has filled the container. These are best for low- to medium-viscosity substances or frothy liquids.

Gravity Fillers for Simple Operation and Cost-Effectiveness 

Gravity filler machines are simple to operate. They rely on the substance's gravity, making them ideal for free-flowing products. Automatic gravity fillers are the best choice for large-scale companies with high production requirements. They are usually connected to conveyance systems and require the least manual operation.

These machines are suitable for non-viscous liquids like water, juices, and beverages. They are also customizable with multiple filling nozzles for efficiency. Machines can be customized with one to 16 fill heads. They also include features such as “no bottle/no fill” sensors, adjustable throttling valves, and bottle backup sensors.

Products Best Suited for Gravity Fillers

Gravity fillers are an excellent choice for many different applications. In the food and beverage industry, they can be used for free-flowing drinks such as water, juices, and soft drinks. They can also be used for laboratory products, such as chemicals, solutions, and reagents. These machines can also be customized with explosion-proof controls so they can be used with other substances, free-flowing such as hand sanitizer. Overall, gravity filler machines are a great option for a cost-effective solution for high-volume liquid filling.

Overflow Fillers and Aesthetically Pleasing Product Packaging

Overflow filling machines achieve precise fill levels every time. These machines feature a specialized two-part nozzle with a supply side and a return side. This nozzle is placed into the container, closing off the opening. The product is then pumped in from a supply line until the correct level is met. 

Overflow Fillers for Uniform Fill Levels and Operation Options

Since overflow filling machines overflow the excess liquid, they ensure uniform fill levels across containers. After the initial pumping phase from the supply line, any surplus product is extracted and pumped back into the original tank, enabling the product to recirculate without spills or leakages. This also allows for very precise measurements. 

Overflow filling machines also come with options for semi-automatic or fully automatic operation. The automatic overflow filler is built with a stainless-steel reservoir that has a product re-supply system and float, and the filler is available with 1 to 16 diving fill heads. The semi-automatic filling machine variation combines manual and automatic operation. It typically includes the same automatic filling mechanism, but an operator is required to load and unload the containers, as well as control the filling process.

Industry Applications for Overflow Fillers

Overflow fillers have very precise filling techniques to ensure even flow levels, making them perfect for many different industries. In the cosmetic industry, they are great for shampoos, conditioners, and liquid soaps. They are also great for household products like detergents, cleaners, and disinfectants. Overflow fillers are especially beneficial for products where customers are able to see fill lines and may be deterred from certain products if the level looks too low such as mouthwash. The machines are the best for ensuring consistent and aesthetically pleasing product packaging.

Choosing the Perfect Filling Machine for Your Business

It is important to understand the different types of filling machines and their functions to make informed decisions for your business. We have discussed automatic pump fillers, piston filling machines, gravity fillers, and overflow fillers, each with unique features and capabilities.

Automatic pump fillers are great for high-volume production and thick products, offering precise filling accuracy and automation. Piston filling machines are perfect for liquids that need precise measurement, accommodating various substances and industry applications. Gravity fillers, which use gravity for operation, are suitable for non-viscous liquids and provide cost-effective solutions for high-volume filling. Finally, overflow fillers ensure consistent fill levels with precise measurements, which is ideal for products where appearance is important.

When deciding which machine to use, remember to consider key factors such as product requirements, production volume, and industry standards. By choosing the right filling machine, businesses can improve production efficiency and maintain product quality, leading to increased productivity and customer satisfaction.