5 Mistakes to Avoid When Installing a New Filling System

Installing a new liquid filling system is a major investment—one that can bring significant improvements in speed, precision, and product consistency. But without the right planning and execution, the installation process can be riddled with preventable missteps that lead to production delays, wasted product, or unnecessary costs.

At Apex Filling Systems, we’ve seen firsthand how a successful installation starts well before the equipment hits the production floor. To help you avoid common pitfalls, here are five mistakes to steer clear of when installing a new filling system:

1. Failing to Assess the Installation Environment

Before your system arrives, it’s critical to evaluate your production space. Insufficient ceiling height, poor airflow, incompatible utilities, or restricted access routes can all complicate or delay installation.

What to do instead:

• Conduct a detailed site survey with your equipment provider.

• Verify space constraints, power and air supply, and flooring load capacity.

• Confirm that the equipment can be safely moved into place without disruption.

2. Overlooking Line Integration Requirements

Your filling machine isn’t an island—it must operate seamlessly with upstream and downstream systems like bottle unscramblers, conveyors, cappers, and labelers. Failure to plan for proper integration can disrupt product flow and reduce throughput.

What to do instead:

• Review the full production line and ensure speed compatibility between machines.

• Consider product and container handling at every stage.

• Involve an integration expert to align timing, height, spacing, and controls.

3. Skipping Operator and Maintenance Training

A high-performance filling system won’t deliver ROI if your team doesn’t know how to run it. Skimping on training leads to inefficiencies, increased wear, and costly mistakes.

What to do instead:

• Schedule training for all operators, maintenance staff, and supervisors.

• Cover startup and shutdown procedures, cleaning protocols, and troubleshooting.

• Request video walkthroughs or easy-access manuals for reference.

4. Ignoring Proper Utility Prep

A frequent cause of delays during installation is missing or incorrect utility hookups. This includes compressed air, electrical service, water supply, or product feed lines that are either incompatible or not ready at time of delivery.

What to do instead:

• Review utility requirements with your supplier in advance.

• Ensure connections meet specs for pressure, amperage, voltage, and flow.

• Test systems ahead of installation to verify readiness.

5. Not Building a Preventative Maintenance Plan

Once the system is up and running, it’s easy to forget about ongoing maintenance—until something breaks. Waiting until failure can lead to extended downtime, costly part replacements, and unplanned service calls.

What to do instead:

• Work with your OEM to create a preventative maintenance schedule.

• Track part life cycles, lubrication points, and inspection intervals.

• Consider implementing smart monitoring for predictive diagnostics.

Set Your System Up for Success

Avoiding these five mistakes can significantly reduce headaches during installation and help you achieve maximum performance from day one. At Apex Filling Systems, we don’t just deliver machines—we partner with you through every step of the process: planning, setup, integration, training, and long-term support.

Thinking about upgrading your filling equipment? Reach out today for expert guidance that ensures your next installation is efficient, future-proof, and production-ready.