Automatic overflow filling machine

Types of Automatic Overflow Filling Machines

Automatic overflow fillers are high-production machines that fill products such as viscous liquids, non-viscous liquids, and products with little to no fill variability. Generally made of stainless steel with aluminum, these units have high-speed conveyor systems that can be adjustable to meet the needs of the specific production line. Products are filled until they overflow into the receptacles. This provides an excellent fill line for products with varying shapes and sizes. Hence, they are suited for everything from the chemical industry to food and beverage aisles. The machine usually comprises a filling machine, hopper, conveyor belt, control panel, and overflow mechanism. Parts can be customizable for safety enclosures and cGMP compliance, among others. Below are some types of automatic overflow filling machines:

• Multifunctional Filling Machine: This particular type of machine comes with several kinds of filling heads to cater to different products. These can include both filling and capping functions, making them a perfect 2-in-1 innovation.
• High-Speed Filling Machines: For industries that require an overflow filling machine at a higher production rate, high-speed filling machines are ideal. These have faster rates of filling but may compromise precision.
• Aseptic Overflow Filling Machines: For products and items that require a sterile environment, such as pharmaceuticals, these provide an overflow fill with microbiological safety.
• CIP/SIP Automatic Overflow Filling Machinery: The devices that support Cleaning in Place (CIP) or Sterilizing in Place (SIP) capabilities allow for the cleaning and sterilization of the filling system without disassembly, ensuring product integrity and hygiene standards. Customization options may be available for cGMP compliance, safety enclosures, and more.
• Automated Overflow Filling Machines: These devices utilize automated fill technology, enabling pre-programming into the control display so that specific volumes can be filled every time. This also includes integration with assembly lines.

Specification and maintenance of automatic overflow filling machines

Specifications

• Speed:

  The speed of automatic overflow filling machines varies depending on the model and manufacturer. On average, automatic overflow filling machines can achieve a speed of 30 to 200 bottles per hour.

• Automatic control system:

  Overflow filling machines control parameters such as filling volume, speed, and timing through an automatic control system. This allows for precise adjustments and monitoring during the filling process. With an automatic control system, the machine can operate independently and efficiently, meeting the production requirements of automatic overflow filling.

• Power:

  Power is one of the important parameters of automatic overflow filling machines, which determines the driving and operating ability of the machines. The power of automatic overflow filling machines are usually between 1 and 3 kilowatts, which can meet the operating needs of various scales. The higher power provides faster and more efficient filling.

Maintenance

In order to have a normal, efficient, and stable performance, it is necessary to do some maintenance of the automatic overflow filling machine to ensure its long-lasting use. Here are some relevant maintenance tips:

• It is necessary to do a regular cleaning of the filling machine by using a mild detergent and water to avoid the residue damaging the machine's functioning. In addition to that, make sure all parts of the machine are dried up.
• Users should periodically calibrate the filling volume and speed of the automatic overflow filling machine to ensure the accuracy and stability of its filling.
• Maintain lubrication of moving parts and components by using proper lubricant to reduce friction and wear, thus prolonging the service life of the machine.
• During the use of the filling machine, users should monitor its operating status and promptly deal with any abnormalities such as noises, vibrations, or faults, which can help avoid potential problems and risks.

Scenarios of automatic overflow filling machines

The food business takes full advantage of these devices. Foods in jars and bottles, such as pickles, mustard, sauces, and others, can benefit from these kinds of machines. Overflow filling machines are extremely versatile, and both their manual change-ups and automatic settings allow them to handle a broad variety of products with different characteristics. Most food, which is required to have a filling capacity, shelf life, and a certain amount per container, is ideal for these machines.

Pharmaceutical drugs that need to be filled to a certain level are also filled using these machines. Syrups and Water medicines in transparent bottles are usually filled using these machines, as well as any other liquid pharmaceutical that must be filled to a certain level for consumers to be sure they got what they paid for and that the medicine will act effectively and as mentioned.

Cosmetic products like shampoos, conditioners, body lotions, and other liquid products are filled using these machines. The overspill feature makes these machines ideal for products where uniformity and precision in the filling process are required. Additionally, the automatic feature of the machine allows for increased production speed, lower labor costs, and more containers filled per hour.

Industrial chemicals are also filled using these machines. Liquid detergent in a bottle and other cleaning products are filled using these machines. Hazardous substances sometimes require hazardous waste solutions for handling them, and using an automatic overflow filling machine is one way to deal with this in a more efficient manner. Chemical products usually also need to have precisely the amount written on the container included inside, so these machines provide a solution to that need.

Beverages, such as juices in plastic containers, are filled precisely to the brim using these machines so that consumers can see exactly how much product they are getting.

How to choose automatic overflow filling machines

When choosing a filling machine, several factors need to be considered to ensure that the right machine is selected for the specific production needs.

• Production requirements

  When selecting an automatic filling machine, it is essential to consider production needs, such as filling capacities, types of products, and bottle specifications. The preferred machine should match the desired filling volume and accuracy to ensure efficient production and minimal waste. For variable viscosity liquids like shampoo and lotion, it may be necessary to use an automatic overflow filling machine combined with another type of filling machine. Choosing the correct combination will depend mainly on the products being filled and the desired level of accuracy and efficiency in production.

• Filling speed and accuracy

  Filling speed and accuracy are crucial factors for production efficiency and cost-effectiveness. Therefore, it is necessary to select the suitable automatic filling machines that can provide the required speed without compromising precision. Consideration should also be given to how the selected machine could impact the overall production line's efficiency.

• Flexibility and scalability

  As demand may change in the future, it is essential to choose a filling machine that can adapt to different products and bottle shapes and has the potential for expansion.

• Integration with production line

  It is essential to choose a filling machine that can integrate with other equipment in the production line, such as capping, labeling, and sorting machines. The selected machine should have the necessary controls and interfaces to ensure smooth integration and compatibility.

• Sanitary requirements

  If the filled product is for the food, pharmaceutical, or cosmetic industry, selecting a filling machine that meets the required sanitary standards is necessary to ensure consumer safety and compliance with regulations.

• Energy efficiency

  Energy efficiency is essential in minimizing operating costs and environmental impact. It is necessary to choose a filling machine that is energy efficient and has low power consumption.

Q&A

Q1: Which types of liquids can an automatic overflow filling machine handle?

A1: Generally, automatic overflow filling machines are designed to accommodate a wide range of liquids. They can handle everything from water, juices and cleaning liquids to industrial chemicals, oils and more. The key factor is the machine's ability to fill products with similar viscosities without causing excess spillage or jamming in the system.

Q2: How flexible are automatic overflow filling machines?

A2: Filling machines are quite versatile. They can accommodate a wide range of products, container sizes and shapes. What is more, they can also be integrated into different types of production lines, be it manual, semi-automatic or fully automatic. Their operating speed can also be adjusted to match the desired filling speed of the product. Generally, they can fill about 30 to 60 bottles in a minute.

Q3: Can one customize an automatic overflow filling machine to meet specific production needs?

A3: Yes. Businesses can request for customizing options to meet distinct production needs.

Q4: Can an automatic overflow filling machine handle products with varying viscosities?

A4: No. As mentioned earlier, not all filling machines can handle products of different viscosities. Only those specially designed to handle products of varying viscosities can do so. Such machines come with adjustable mechanisms that allow them to handle products of different viscosities. Also, they come with specialized filler nozzles that can be used to fill products of different viscosities.