Filling Machines: Eliminating Drips
Product drips from a liquid filling machine present one frustrating issue that may be experienced by a range of packagers. Even small drips of product following a fill cycle can create a chain reaction that can lead to lost product, messy or sticky containers, inaccurate fills, slippery conveyors or a host of other issues ranging from inconvenient to costly problems. Fortunately, most post-fill dripping can be prevented through the use of the proper equipment, adjustments to the machinery, or nozzle design. At Liquid Packaging Solutions, Inc. , we engineer filling machinery with these challenges in mind, helping manufacturers achieve clean, consistent, and efficient fills.
WHY DO FILLING MACHINES DRIP?
There is no one, single reason as to why a filling machine may drip product after a fill. The causes of dripping often depend on the product being packaged and the filling principle being used on any given project. Thin liquids may simply continue to flow due to momentum, while thicker products may cling to the nozzle and slowly release after the fill. Other product characteristics, like foamy liquids, liquids with suspended solids, or temperature sensitive products can all present dripping challenges. Common issues that contribute to dripping include:
- Improper nozzles
- Worn seals or other wear parts
- Inconsistent product pressure
- Incorrect fill times
- Product buildup, especially on nozzles
- Poor maintenance
Identifying the cause or causes of the drip will be the first step in eliminating the same and improving overall packaging.
PRODUCT CHARACTERISTICS
As noted above, the characteristics of a product can contribute to the drip. Different liquids behave in different ways during the fill process. Viscosity, temperature, foaming and particulates can all influence how a product exits the nozzle. A liquid filling machine manufactured for a free-flowing, water-like liquid would likely need adjustments, often including different nozzles, if it were to run lotions, sauces, syrups, or other thicker liquids. Understanding the characteristics of the products that will run allows the machine to be engineered, built, and configured with the right components to eliminate dripping.
USING THE RIGHT FILLING NOZZLE
Not every filling machine or packaging project uses the same nozzle design. Choosing the correct nozzle can significantly reduce dripping while also improving fill accuracy. Positive shut-off nozzles, for example, are designed to stop product flow cleanly once the fill cycle is complete. Diving heads can minimize splashing and foam by filling from the bottom of the container and slowly rising. Other custom nozzles can help prevent dripping when dealing with stringy, high viscosity, or other unique liquids. Matching the appropriate nozzle to the product or products of an individual project is one of the simplest and most effective ways to improve filling performance and control dripping.
PROPER MACHINE MAINTENANCE
Simple visual inspections of filling machines and nozzles is the best place to start routine maintenance. Nearly all, if not all, filling machines will include seals, O-rings, valves and other components that will wear or deteriorate over time. Worn parts can lead to small, hardly noticeable leaks that can gradually increase dripping over time, while reducing fill consistency and increasing product loss. Preventative maintenance helps to ensure all wear parts are replaced in a timely manner while also ensuring product build up on nozzles or components does not occur. Keeping the components effective and clean is one more way to prevent dripping on the liquid filler.
LINE INTEGRATION AND SYNCHRONIZATION
Believe it or not, drips can be caused by something other than the filling machine. For instance, if conveyors or conveyor speed is not synced along the entire line, bottle movement in the filling machine may occur too soon! If bottles begin moving out from under fill heads at the wrong time, product will drop outside of the bottle opening, causing not only unclean bottles, but the potential to transfer the mess along the entire conveyor system and packaging line. Proper synchronization between all of the machines on a packaging line and the conveyors not only stops drips but prevents a drip from becoming a bigger problem for production.
At LPS, we understand that achieving a clean fill involves more than just dispensing liquid into a container. Every filling machine we build is engineered around the customer's products, container, production goals, and environment. Whether packaging beverages, cosmetics, chemicals, or liquids from any other industry, our custom - and properly - engineered filling machines can help eliminate post-fill drips while also improving packaging appearance and production line efficiency.