The Apex Guide to: Overflow Fillers

When liquid products are lined up in transparent bottles on the shelves in a retail store, they make the best impression if the fill levels of each container are consistent all the way across. One obstacle to achieving this pleasing uniformity is that containers – especially ones made of glass – sometimes have irregular shapes on the inside. If the exact same quantity of product is put into irregular containers, the fill levels won’t match, and the containers will (incorrectly) appear to each have different amounts of product in them.

There are some cases where this would not be a cause for concern. For example, a vial holding a single dose of medicine must have the precise amount of content, no matter what it looks like. Another case is when the container is opaque enough that the fill line is invisible.

Maintaining uniform fill levels matter most for retail items where the customer is making a decision based in part on how the products look. A row of bottles of mouthwash with different fill levels can give the impression that the company is careless in its manufacturing, and the customer may decide to move down the aisle to select a different brand. A container with a noticeably low fill level may also be the last one left on the shelf, until finally the retailer has to return or discard it, wasting money for the manufacturer. Adjusting the actual volume by an almost imperceptible amount won’t affect the value a customer gets from the product, but it could have a big impact on sales.

The Overflow Filler Difference

Overflow fillers are designed to produce a cosmetic fill level every time. These fillers use a special two-part nozzle that has a supply side and a return side. The nozzle lowers into the container and seals off the opening. Then the product is pumped in from a supply line until the correct level is reached. Any excess is then extracted and pumped back into the original holding tank, allowing the product to recirculate, and the seal over the container opening keeps the product clean while preventing spills or leakage.

The height of the fill line is set through the use of spacers on the nozzle, which sets the location of the overflow port. They can be adjusted easily so that the machine can transition between jobs with different fill levels.

The Best Liquids for Overflow Fillers

Overflow fillers are meant to be used with low to medium viscosity liquids and foamy liquids (non-carbonated). They can also process these same fluids with the addition of particulates that are 1/16” in size or smaller. Specific applications include personal care, cleaning chemicals, pharmaceutical, cosmetic, beverage and food.

Economy Automatic Overflow Filler

Our Economy Automatic Overflow Filler is built with a heavy-duty 304SS tig welded frame, Allen Bradley PLC, and a touch screen operator interface. The stainless-steel reservoir has a product re-supply system and float. The filler is available with 1 to 16 diving fill heads. This level of automation is appropriate for businesses that have increasing demand needs.

Similar to our other machines, the features of this filler also include:

• No bottle/no fill sensor
• Automatic indexing gates
• Front panel start and emergency stop
• Container counter
• On/off and speed controls for conveyor
• Bottle back up sensor (downstream) delays filler operation until jam is cleared
• Tool-free adjustment
• Upgradeable
• Made in the USA

Customization Options

We will work with you to create the filling system that is best for your business. Customization options include:

• Automatic drip tray
• Bottle grabbers/neck grabbers
• Star wheel or timing screw indexing
• Clean-in-place system
• Hazardous location/environment construction – Class I, Division II, Group C&D
• All-pneumatic construction
• Corrosion resistant construction, including all contact parts
• Sanitary-style construction
• High-temperature applications
• Fill head sizes available from 1/4″ up to 1½”

Our customization also includes all the components of a larger system, which can include labeling, capping and conveyance solutions. We are committed to helping our customers design the system that helps them meet their current and future needs.

One of the most important aspects of retail marketing is making sure your packaging looks good, and for liquid products that usually includes having professional, uniform fill lines. Overflow fillers meet that important need in a cost-efficient way, while helping your staff reach their production goals.

Let Apex Help You

Apex offers all of our clients customized solutions to their filling needs. Call us at 219-575-7493 or visit our page here to discuss the best equipment choices for you.

Alicia Cannon

Integrity, honesty, and a dedication to delivering ambitious results serve as the central themes of Alicia’s career and are evident in every interaction she has with our clients. Her relationship-centered leadership style has paved the way for Apex Filling System’s culture of compassion & empathy, executed with accountability that ensures consistently great outcomes. As a learner for life, her pursuit of continuous personal and professional growth has led Apex Filling Systems to be recognized as an industry innovator in customer experience. Holding advanced degrees in the areas of engineering and management, she has a unique ability to analyze processes, identify potential problems before they arise, and develop standardized solutions to ensure every client of Apex Filling Systems enjoys a hassle-free, professional, and pleasant experience. Her leadership style has been influenced by the work of some of the most well-regarded thought leaders throughout the last 50 years. Among them are Jim Collins, Sally Hogshead, John Maxwell, and Tony Robbins.