Filling Foamy Products - The Bottom Up Fill Solution
One concern that arises among packagers on a common basis is the filling of foamy products. The issue arises somewhat frequently simply due to the fact that there are many products that create foam when agitated. From beverages to soap products, cleaners, chemicals and more, creating foam during the fill process can result in inaccurate or inconsistent fills. While several different methods exist to control foam during a product fill, for those using a volumetric filling machine, utilizing a bottom up fill may be the most common method.
As agitation can set off a foamy reaction, bottom up nozzles work to reduce the amount of agitation during the fill. These nozzles will dive into the bottle before opening and releasing product into the bottles or other containers. Once the nozzles are lowered near the bottom of the container, the valves will open and product will be released. Nozzles will then slowly rise as product is released, reducing agitation and splashing and in turn minimizing or removing foaming from the fill.
The speed of the nozzles as they rise during the fill can be adjusted to fit the needs of the packager and the product. This method of filling can also be used with different nozzle sizes, which means containers both large and small can benefit from the bottom up fill. The speed also allows the bottom up fill to work with both high and low viscosity products. In order to work effectively, the nozzles should remain just above the liquid level in the bottles during the rise. Thick products may require a slower ascending speed than free-flowing liquids. The speed of the nozzles when rising will typically be easily adjustable from the Operator Interface on automatic machines using this technique. In other words, an operator simply needs to pull up the proper menu and add or subtract speed from the ascending by pressing a button.
While bottom up fill nozzles are a popular method to help control foaming, there are other solutions for different packagers and products. For those using a fill to level system, overflow fillers provide a solution as well. For those experiencing issues with foamy product, Liquid Packaging Solutions suggests a free consultation with a Packaging Specialist. LPS representatives will discuss all aspects of a packaging process to identify the best solution to control foamy products. For assistance, simply fill out the Quick Connect form found on each page of the LPS website or call 1-219-393-3600 today.