Bottle Filling and Capping Machine – The Ultimate Guide

Bottle-filling machines fitted with capping machines are some of the equipment used to automate a production line. There are a multitude of benefits that accompany automating production including increasing the scale of production.

The machines can be incorporated into the production and packaging of various liquids making it incredibly versatile.

What is a Bottle Filling and Capping Machine?

This a two-part machine that is used to package contents onto bottles and seal them. The machine is equipped with a filling station which may vary depending on the manufacturer. Some of the general parts of the filling station include syringes and nozzles.

The capping unit on the other hand comprises a stopper and the capping tool. These machines have features that differ according to brand. Although they serve the same function they may utilize different tools to carry out this function.

Bottle Filling and Capping Machine
Bottle Filling and Capping Machine

Advantages of Bottle Filler and Capping Machine

There are several benefits when you incorporate this dual machine into your production line. These benefits include;

  • This equipment helps to significantly boost your scale of production. This is achieved by packaging more bottles while minimizing errors that often lead to wasted time and resources.
  • The filling process conducted by the machine is very accurate as it quickly dispenses the set amount of fluid into the bottles.
  • The machine reduces the amount of manual labor required to execute the process. As such it will help you minimize your costs of labor and also eliminate human error that is likely to occur.
  • These general devices can be used for a broad range of applications and are suited for several different fluids. You can therefore use the machine to package different products.
  • Minimal interaction with the filling and sealing of the product greatly reduces the risk of contamination from external sources. It also increases the hygiene of the operations and the machines can easily be cleaned reducing the risk of contamination.
  • There will be little to no product lost during the packaging post. The machine accurately fills the bottles with the required amount with minimal errors that require the discarding of packaged products.

How to Choose Bottle Filler and Capping Machine

Some factors should be considered when selecting the bottle filler and capping machines. These factors include;

  • You should take into consideration the type of fluid and its properties. There are different variations of machines with features that are adaptable to various products. It is best for you to select a machine that is most suitable for your product range.
  • The production capacity of your application should also be considered. There are different scales of machinery ranging from small devices suitable for small-scale enterprises to industrial-grade machinery used by large-scale enterprises. Larger machines tend to cost more and will be a loss if used for small-scale applications.
  • The type of packaging is another factor that will influence your choice of machinery. The material used for the machine and the shape of the container will determine the types of equipment required to both fill and cap the container. You should consider a machine that will accommodate the different types of packaging you have.
  • These machines have varying levels of automation ranging from semi-automatic to completely automated. Depending on your processing scale and requirements you can opt for or the other. Semi-automatic machines require additional labor to complete some processes.
  • Some variation of these packaging machines requires more maintenance than others. More complex designs may require expert help when undertaking maintenance to ensure that remain fully operational. Simpler designs are easier to maintain and will be easier for you to carry out routine procedures.
  • In case you have plans to upgrade your scale of production the machine you select should also have room for future expansion. It should also be durable so that it can be used for a long time.

Types of Bottle Filler and Capping Machine

There are a multitude of different bottle filing and capping machines. They are each categorized according to their distinctive features. These types include;

Mechanical Operated Bottle Filling and Capping Machine

This type of bottle-filling machine relies on a series of mechanical operations to perform its various functions. It comprises a bottle separator that spins freely without the assistance of any pneumatic operations which minimizes its turn-over period. The machine is designed with a fully automated system that consists of bottles automatically being fed into the system as well as capping and exiting the system.

Mechanical Operated Bottle Filling and Capping Machine
Mechanical Operated Bottle Filling and Capping Machine

Electronic Liquid Filling and capping Machine

This variation of the bottle filling and capping equipment relies on sensors and electronic control systems to allocate products into their bottles and capping. The devices have elevated accuracy when it comes to dispensing products and can easily be integrated into an already existing system. These types of equipment are also designed in a variety of configurations that are suited for various applications.

Electronic Liquid Filling and Capping Machine
Electronic Liquid Filling and Capping Machine

Servo-Driven Bottle Filling and Capping Machine

This variation derives its name from its primary driving mechanism which is the servo motor that is used to power the system. The equipment is controlled using a Programmable Logic Controller that is fitted with a digital interface that is user friendly making it easy to operate the system. These machines are incredibly versatile and you can use them for a wide range of applications involving various liquids and containers.

Servo Driven Bottle Filling and Capping machine
Servo Driven Bottle Filling and Capping machine

Gear Pump Based Bottle Filling and Capping Machine

A gear pump-based bottle-filling machine has a gear pump as its primary powering mechanism. The gear pump delegated for this function is a positive displacement pump which siphons your product from its reservoir and into the different bottles. This mechanism is ideal for small-scale to medium-scale operations and is suited for a variety of products.

Gear Pump Bottle Filling and Capping Machine
Gear Pump Bottle Filling and Capping Machine

Peristaltic Pump Type Bottle Filling and Capping Machine

A peristaltic pump-type bottle-filling machine as suggested by the name utilizes a device known as a peristaltic pump to carry out its operations. The pump is fitted with mechanisms that compress the attached tube which creates a vacuum that draws in your product and drives it forward. This device is best suited for small-scale operations that involve light liquids.

Peristaltic Pump Bottle Filling and Capping Machine
Peristaltic Pump Bottle Filling and Capping Machine

Digital Liquid Filling and Capping Machine

This is a high-tech device equipped with digital controls and displays that allow you to set the required parameters as well as seal the finished product. Their digital controls offer a quick and accurate method of adjusting settings in terms of the volume of product dispensed into the different containers. These devices are designed with a pump capable of self-priming that has the ability to the product from bottles making them convenient to use.

Digital Liquid Filling and Capping Machine
Digital Liquid Filling and Capping Machine

Flameproof or Explosion Proof Filling and Capping Machine (ATEX certified)

If your application involves flammable or volatile products then this device is the best filling and capping machine for you. This variation that requires ATEX certification is proofed against explosions and ignition of flames. These systems are equipped with a multitude of safety features that minimize and mitigate any accident that may occur during packaging. These features include suppression systems, flame arresters, and explosion-proof enclosures.

Explosion Proof Bottle Filler and Capping Machine
Explosion Proof Bottle Filler and Capping Machine

Monoblock Bottle Filling and Capping Machine

This device consists of a singular block of an integrated system that comprises a filling and capping station. These devices come in a range of configurations that utilize different mechanisms to perform their function. The most suitable variation of this device for you depends on the type of product you wish to package.

Monoblock Bottle Filling and Capping Machine
Monoblock Bottle Filling and Capping Machine

Common Parts in Bottle Filling and Capper Machine

There are many variations of such machines and as such the part may vary from one design to the next. The most commonly incorporated parts of these machines include;

  • Filling head: This is the part of the machine tasked with allocating the various products into their respective. The section comprises various components including nozzles and syringes which may vary according to the design.
  • Bottle stopper: This section is responsible for aligning the bottleneck to make sure that the bottle is correctly filled.
  • Conveyor belt: This is the compartment responsible for moving the containers from one section to the next.
  • Capping mechanism: This is a section that is tasked with putting on and securing the caps onto bottles that have been filled with products. the parts may vary depending on the configuration. The parts included in this mechanism include; discs, pumps, and rollers and may differ depending on the manufacturer.
  • PLC control: The Programmable Logic Controller is the system used for controlling the filling and capping process. This control is used to adjust the different parameters such as torque and volume.
  • Bottle counter: This part is used to keep track of the bottles counted.
Parts of a Bottle Filling and Capping Machine
Parts of a Bottle Filling and Capping Machine

How Bottle Filling and Capping Machine Works

Technologies in Bottle Filling Process

The bottle-filling machine is a supplementary system that is incorporated as a final step in the production process. Once the product is finalized you can have an automated system that feeds the product directly into the system. Semi-automated systems may require manual labor to feed the system.

Bottlefilling involves the following steps;

  • The first step is loading the bottles onto the conveyor belt.
  • You then set the parameters such as the volume of the product into their designated containers.
  • The filling head then injects the specified product into the containers using a rotation valve. Other designs use a plunger for this reason.

Bottle Filling Technologies

  • Timed flow filling
  • Fill to level filling
  • Piston filling
  • Metered flow filling
  • Positive displacement pump filling
  • Gravity filling
  • Electronic filing

Bottle Capping Process

The bottle capping process involves setting the delegated caps onto the filled bottles and then securing the cap to seal the container. This process is carried out using various components which differ depending on the manufacturer and type of equipment. The components include discs, pumps, and rollers

Bottle Capping Technology

  • Spindle Capping Machines
  • Chuck Cappers
  • Snap Cappers
  • Tabletop Screw Capping Machines
  • Automatic Multi-Head ROPP Capping Machines
  • Single Head ROPP Capping Machines
Bottle Filling and Capping Machine Working Principle Flow Chart
Bottle Filling and Capping Machine Working Principle Flow Chart

Applications of Bottle Filling and Capper Machine

Bottle-filling and capping machines come in a variety of configurations each one adapted to package a range of products. These machines are very versatile and can be used to package products with different characteristics ranging from liquids to powders. Some of the industries that use this machine include;

  • Water and Beverages.
  • Pharmaceuticals
  • Cosmetics
  • Chemicals

Conclusion

Understanding the different types of bottle-filling and capping machines will help you determine the best machine for your applications. You should select one that can accommodate all your products as well as one that will cater to your needs including expansion of production scale.

More Resources:

Reasons to use Automatic Liquid Filling Machine – Source: LOM

Bottle Filling Machine – Source: LOM

Filling Machines – Source: WIKIPEDIA

Semi-automatic Liquid Filling Machine – Source: LOM

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