Filling Machine Problems and Solutions

Filling machines, just like any other complex equipment are prone to a range of functional problems.

Identifying and resolving these challenges promptly guarantees streamlined production operations. In addition, this significantly increases the reliability and lifespan of these machines.

Today, we will explore some of the most common problems you will experience when using filling machines and possible solutions:

1. Wear and Tear

Manual Filling Machine
Manual Filling Machine

Wear and tear is a natural phenomenon with all types of complex mechanical systems and filling machines are not an exception.

The service life of filling machines is 5-10 years. Wear and tear can contribute to the shortening of this life span significantly.

Several factors cause wear and tear in filling machines. These include:


Rust and oxidation are the main contributors to corrosive wear. This is usually because of chemical reactions intensified by temperatures. Other causes are moisture, corrosive gas, or liquid.


Due to the repetitive mechanical system of filling machines they are susceptible to fatigue wear. The continuous moving and rolling of parts can cause small breakages which can interfere with the smooth operation of filling machines.


Filling machines consist of a variety moving parts. Adhesion brings about friction when the load in the machine transfers to other moving surfaces.

Friction wears out moving parts of the machine and can eventually cause permanent damage.

Solution to Wear and Tear

Regular Cleaning and Lubrication

Lubricating the moving parts filling machine frequently aids in reducing friction, heat and other factors that cause wear.

Cleaning on the other hand gets rid of any accumulated dirt and debris that might damage or clog the machine.

Frequent Inspection and Monitoring

Regular inspection for leaks, cracks, unusual vibrations, and sounds can help identify wear and tear early on.

Monitoring entails taking measurements and recording parameters such as temperature, speed, pressure, and efficiency.

Repair and replace Promptly

Timely replacement and replacement of faulty parts is another way of protecting your filling machine from wear and tear.

Replacing involves removing old and worn-out parts with new or functional ones. Repairing involves upgrading, fixing, or restoring broken and faulty parts.

2. Inaccurate Filling Volumes

Filling technologies
Filling Technologies

Another intricate fault that you can find in filling machines is inconsistent filling volumes. This complex problem can emerge from different sources within the machine.

For instance, if there is any foreign matter stuck in the control valve, it can cause inaccurate filling volumes.

It is paramount to note that even air trapped in the quick control valve can cause discrepancies in filling volumes.

Worn out valve core and speed throttle can also bring about inaccurate filling volumes. Aged peristaltic components as well as peristaltic pump tube can contribute to inconsistency in the filling volumes.

Other causes for this challenge are:

  • PLC settings
  • Fast filling speed
  • Inadequate filling material
  • Clogged filter

Solutions for Inaccurate Filling Volumes

Get rid of any foreign matter that could be stuck in the control valve. If there is any air in the quick installed three-way control valve, remove all of it or try to reduce it.

Other corrective measures you can implement include:

  • Repair or replace any worn-out components especially valve cores, with new ones or upgraded ones.
  • Clean both the filter and the filter nozzle to get rid of clogging.
  • Check and remove any impurities in the filling material.
  • Ensure that the filling speed is not too fast. If it is ahead adjust the throttle value to reduce the speed.
  • Confirm that there are no air leaks on the hose fittings, clamps as well as the air connections. If you detect any leaks, replace any aged or damaged seals, if loosened, fasten them.

3. Material Leaking

This problem is most common with liquid filling machines. There are several probable causes to this problem.

Damaged O-ring on the Piston

There are several factors that can cause damage of the o ring. These include friction, corrosion, and deformation due to pressure, material selection, and excessive temperature.

Unfastened piston and piston rod. Also note that over-tightening both parts can cause deformation, cracks, and fractures.

Another cause of material leaking is displaced material cylinder. You should always position the cylinder of the cylinder bracket.

Solutions for Material Leaking

Replace the damaged o ring with a new or upgraded one. To prevent future damage, ensure to use the right filling material, lubricate to avoid friction damage, and clean regularly to avoid corrosion.

Ensure that you securely tighten the piston and piston rods – neither too tight nor too loose.

Reinstall the misplaced cylinder to the ideal position which is in the middle of the cylinder bracket.

4. Nozzle and Seal Problems

Liquid Filling Nozzle
Liquid Filling Nozzle

The filling process requires both high precision and functional proficiency. In this case both the sealing mechanisms and filling nozzle should exhibit operational integrity.

This is not always the case always as the nozzle and seal can develop a number of challenges.

Nozzles can accumulate build up of foreign material which can cause them to clog and then eventually malfunction.

Nozzles can also have damage resulting from general wear and tear.

Seals on the other hand can fail due to the following causes:

Improper Installation

Installing the seals in the incorrect direction can cause seal damage. Using a less robust material can also cause damage and shortened life span.


The filling machine system operates in high pressure which can potentially cause breakages and leakages.

Nozzle and Seal Solutions

To ensure there is no clogging of nozzles, conduct regular cleaning and maintenance.

Get rid of any foreign material and remove any build-ups.

Regularly inspect the nozzles for any damage or wear. Replace worn-out and aged ones with new or upgraded ones.

For seals, implement regular preventative maintenance as well as cleaning. This also includes timely replacement of old and damaged seals.

During installation, use the correct tools and ensure to install the tools in the right direction.

Use seals made out of sturdy materials such as thermoplastics to avoid regular damage.

5. Electronic Problems

Filling Machine PLC System
Filling Machine PLC System

All types of filling machines are susceptible to electronic control faults especially those connected with the power supply unit.

This problem is not confined to one cause as it can arise from any component of the electrical infrastructure. It can be plugs, power sockets, fuses, or even circuitry connections.

Outdated software is another factor that can cause electronic malfunction. Of course, this not only causes downtime but also a flawed filling operation.

Old and poorly maintained electrical components can contribute to the development of this problem.

Solutions to Electronic Problems

Electrical malfunctions especially those associated with power supply units can cause significant disruption in the production line.

It is therefore important to have the knowledge to prevent these faults and how to sort them when they arise.

For instance, regular inspections of the electronic components can aid in identifying faulty or damaged for timely replacement and repair.

Additionally, making sure that systems are kept updated with the latest advancements is a vital strategy to ensure seamless filling system operations.

Another imperative way to deal with these complex problems is to equip the operational personnel with troubleshooting techniques. There should also be an emphasis on maintenance tips and proper handling of electronic components.


It is evident that managing and resolving inherent faults found in filling machines is vital in ensuring continuity in the production of this critical industry.

Therefore, it is indispensable to have an in-depth knowledge of potential challenges as well as the resolution techniques.

More Resources:

Filling Machine Spare Parts – Source: LOM

Filling Machine – Source: WIKIPEDIA

Liquid Filling Machine Parts – Source: LOM

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