How to Choose the Right Filling Machine

When it comes to liquid filler machines, there are many options to choose from. Some common types of liquid filling machines include piston fillers, overflow fillers, gravity fillers, and pump fillers. Each type of machine operates differently and is designed to work with different types of products. 

Selecting the right liquid-filling machine for your industry is essential to ensuring your products look and work their best. Without a structured approach, many companies risk investing in equipment that may not efficiently meet their production needs. This can cause a variety of issues, such as productivity losses, quality issues, and increased costs. 

While the type of liquid filling machine has an impact on many factors, some of the most common features it has an impact on are material compatibility, speed, accuracy, scalability, and various filling methods.

Finding a Machine to Match Material Compatibility

One of the most important considerations for determining the ideal liquid filler machine for your product is material compatibility. Depending on the material your product is made of, some machines may work poorly for filling your container, or they may be ineffective for your intended use altogether. 

Each type of machine uses different methods for pushing liquids through and measuring how much is being added to the container. Before making a final decision on what liquid filling machine is best for you, it is important to pay attention to factors such as your product's viscosity, abrasiveness, how hard of a push it needs to move, and the shape or volume of the containers you want to fill. 

Typically, piston fillers work best for thicker products, semi-solids, and products with particulates. Thinner products usually work best with pump fillers and overflow fillers. Thin and medium viscosity products often work best with gravity fillers.

Some ways to tell if a certain liquid filler machine is good for your product is by first identifying if it is a thin or water like substance, if it is a powder, or if it is a thicker substance. Some equipment options, like piston fillers for example, are more flexible for dealing with thicker products, while machines like pump fillers or gravity fillers are better for thinner and more free-flowing products. You’ll also want to determine your fill preferences, as some machines fill based on certain volumes while others are time-based. Finally, if your product is considered sanitary, hazardous, flammable, or corrosive, some fillers, such as overflow fillers, may not be the best option. 

Speed and Accuracy for Better Production Rates

Liquid filler machines are designed to fill containers more quickly while maintaining accuracy. Before deciding on a machine, it is important to make sure it can efficiently do both for your product. While some smaller businesses may be able to get away with trading off some of the speed components for a lower price, this is very important for businesses with higher production rates. 

Smaller machines are often measured by the number of bottles they can produce in an hour, while larger, more efficient filling machines are rated by the number of bottles they can fill in a minute. Different aspects of the machine also impact speed and accuracy. For example, semi-automatic machines are faster than manual machines. However, fully automatic machines are even faster. 

Accuracy can also be affected depending on the type of machine and the type of liquid being used. While machine-like pump fillers are good for all viscosities, gravity, and piston fillers have more specific volumetric filling uses. For faster fill rates, pressure-overflow fillers are also often used to prevent overflow and spilling.  Hoses, internal seals, nozzles, and valves also need to be compatible with your product. 

Planning for Scalability and Future Growth

It is important to plan ahead for your growing business. It is easier to get better equipment to start with than to upgrade to a different machine later as your business continues to grow. This is why it is best to make purchasing decisions with a future-growth mindset. 

When looking for a liquid filling machine, look for one that can scale with your business. This means finding a machine that can keep up with higher production demands, changing products, and changing container shapes or sizes. For example, servo liquid filling machines can be programmed to different sizes and viscosities, so they cover being able to fill multiple different types of products with easier changeovers. 

Additionally, there are different types of style machines to consider, such as linear packaging machines and rotary packaging machines. While rotary machines are known to increase production volumes by providing a continuous output, linear packaging machines are known to be more scalable are able to be adjusted quickly and easily for seasonal demands or other changing production needs.

Piston filler machines are also known to be one of the more scalable liquid filler machine types. Since they fill containers by volume, they are easily adaptable to different products and container sizes. However, sometimes changeovers can be a little more complicated. 

Overflow Filling for More Even Fill Levels

Overflow filling is a type of liquid bottle filling machine method used to ensure that bottles are filled at the same level. However, since this method involves focusing on the fill level, sometimes the volumes between bottles may be uneven. 

Overflow filling is great for making more visually appealing bottles, making it extra good for clear containers. Even fill lines also prevent customers from buying items they believe to have less product inside because of varying bottle volumes that could cause uneven fill lines. 

These types of liquid filling machines are best for thin to medium viscosity products. They are also able to fill products quickly and put the leftover product back into the storage tank so that nothing is wasted. When choosing filling equipment, make sure you are using containers where bottles are mostly even, and the appearance of an even line outweighs the need for exact measurements. For example, this may work better for perfume than liquid medicine, where precise measurements are more necessary. 

Piston Filling for High-Volume Industrial Needs

Piston liquid filler machines are for products with viscosities ranging from thin to thick. They also are compatible with semi-solids and liquids with particulates. These are highly customizable and work great for high-volume industrial needs. They work by filling containers with precise amounts of product from a bulk tank that uses a level-sensing float, a manifold with directdraw, or recirculation methods.

There are more economical options. However, there are also many customization options for suiting more high-volume industrial needs. There are also table-top semi-automatic options for enterprises. Customization features, like adding a heated hopper for thicker liquids, are available for more even and efficient filling. 

Some of the best-suited products for piston liquid filling machines include pharmaceuticals, essential oils, and THC and CBD tinctures. These work especially well with higher-cost liquids that require exact amounts. As with any machine, it is important to routinely check it and make sure whatever products you are using are not clinging to the inside, as this may impact its functionality. This is extra important for stickier and thicker liquids.

Gravity Filling for Low-Viscosity Liquids

Gravity liquid filler machines are the more economical option. They work best with low-viscosity or frothy liquids. These machines store liquid above the bottles as they are filled and let gravity help with the rest of the process. This is a type of volumetric time-based machine that uses repetition to create accurate fill volumes.

These types of machines can work with a variety of different products. Some industries they are commonly used for include food and beverage, cleaning and specialty chemical, pharmaceutical, cosmetic, and personal care industries for various filling projects. They also are able to be used for some sanitary, hazardous, flammable, and corrosive products.

For best performance, this machine should not be used for products of higher viscosities that need extra assistance to move smoothly through the machine. Because this machine uses gravity to assist movement, thicker liquids may get stuck or move through the machine less successfully. 

Pump Filling for a More Versatile Solution 

Pump liquid filler machines are another option. They use force to help pump the product through the machine. These types of machines are some of the most versatile to use because they are compatible with even the thickest products. This includes those that drip, stretch, or contain large chunks. 

Although they are more commonly used for products that are harder to work with — such as honey, salsa, or car wax — they are also compatible with more watery, low-viscosity products too. This makes this machine very easy to scale and keep up with changing needs. 

These machines come in industrial and semi-automatic tabletop options. They are also compatible with many products classified as sanitary, corrosive, flammable, or hazardous. For best results, make sure to match pump specifications to your specific application requirements and routinely inspect the machine.

Find Your Ideal Solution With Apex Today

With so many different filler machine options to choose from, it can be hard to determine which machine is best for day-to-day operations alone. For additional guidance about your different options and how to get the greatest ROI, consider speaking with a trained professional in the industry. 

Apex delivers personalized solutions for each of our clients' filling needs. To learn which filling solution is best for your business, call us at 219-575-7493 or visit our page here.