Liquid Filling Machine Troubleshooting

Liquid filling machine is used to deposit liquid materials into bottles, jars, or containers for packaging, usually from a large storage.

The machine can malfunction at any time leading to a troubleshooting process to assist find the fault and fix it.

Steps in Troubleshooting Liquid Filling Machine

Liquid Filling Machine
Liquid Filling Machine

Troubleshooting is the process of finding a problem or malfunction of the filling device with the aim of correcting it.

The following steps can be used to ensure you correctly identify the problem and fix it.

1. Read Manufacturer’s Manual

Going through the user manual helps you understand the functionality of different parts and components of the liquid filling machine. This information together with the safety precaution methods can guide you in identifying problematic areas.

2. Zero in on the Problem Area

The next step is to locate the specific area where the issue could be using one of your senses. By observing the machine, you can identify any mechanical faults, leakages, blockages, loose parts, etc.

Listen for any weird noise from the machine or whiff for any burning smell emanating from or around the machine.

3. Determine Possible Cause

List down all the problems identified in step two and use the guide to identify the possible causes.

4. Develop Plan of Action

Armed with a list of faults and their causes, you can now draw your plan of action to help fix the issues.

Some of the possible troubleshooting techniques include; repair, replacement, adjustments, cleaning, and maintenance.

5. Implement your Plan

Here you carry out the actual solution like unblocking nozzles, replacing worn-out parts, fixing adjustments, etc. whatever works.

6. Test the Machine

Finally, you need to test-run the machine to check if the problem is fixed or if there is any other fault.

7. Solution Documentation

After a successful test run and the liquid filling machine is verified, the solution implemented is properly documented for future reference.

The documents can be used to train new machine operators to enable them to troubleshoot the machine for similar issues.

Liquid filling machines have come in different types such as manual, semi-automated, and fully automated.

While the troubleshooting steps mentioned above cut across the different machine types, the techniques to use are unique to each machine.

Troubleshooting Tips forSemi-Automated Liquid Filling Machine

Liquid Filling Machine Parts
Liquid Filling Machine Parts

A semi-automatic liquid filling machine is operated by humans and is run by either compressed air or electricity or both. They are applicable in small-scale production due to the number of packaging it can handle per production.

 ProblemPotential CauseSolution
1Switchbutton remains OFF when plugged in.1.       Loose plug connection.


1.       Disconnect plug and reconnect properly.
2.       Defacedpower plug.


2.       Replace the damaged power switch.
3.       Poor power switch contact to power source.


3.       Plug back the wire to the switch button.
4.       Damaged wire.4.       Repair or replace the broken wire.
2Inaccurate filling volume1.       Clogged filter.1.       Remove the filter and clean/unclog.
2.       Filling liquid is contaminated.2.       Purify the filling liquid.
3.       Blocked filling spout3.       Unclogfilling spout.

Electrically powered semi-automatic liquid filling machine


 ProblemPotential CauseSolution
1Malfunctioned Cylinder.
  • Non-functional pressure gauge
  • Connect the machine to the air source
  • Examine the fixed reed switch position
  • Reposition the reed switch at the back of the cylinder
  • The emergency button could be pressed down
  • Release the emergency button by twisting it
  • Blown fuse
  • Install a new fuse
  • Inspect to see if the piston is stuck.
  • Replace with a new piston.
  • Look out for a sticky O-ring.
  • Ensure the sticky O-ring is replaced.
  • Filling port core could be stuck.
  • Install newfilling port core.
  • Moving the reed switch position is beyond the maximum filling volume level.
  • Fine-tune the switch position to the correct level.
2Irregular fillings or None at all.
  • The moving reed switch is unsecured.
  • Secure the front reed switch and ensure the correct filling volume.
  • The control valve is probably closed.
  • Open the control valves.
  • Fast filling speed.
  • Reduce throttle value to reduce fill speed.
  • Look out for stuck filling port core.
  • Install the filling port core again.
  • Inspect the O-rings and seal for any damages.
  • Install new rings and seals.
  • Confirm if their air leaks around joints.
  • Remove damaged seals and replace them with new ones.
  • Confirm if the storage tank has enough liquid product.
  • Ensure there’s sufficient filling material in the reservoir.
3Piston cannot pull back.
  • Verify moving reed switch position.
  • Engage emergency stop and reposition the reed switch.
4Filling material leaking .
  • Examine the O-ring for any damages.
  • Install new O-ring.
  • The piston and piston rod are loose.
  • Tighten loose piston and piston rod.
  • The material cylinder is not at the center of the cylinder holder.
  • Reposition the material cylinder correctly.

Compressed air semi-automatic liquid filling machine

Troubleshooting Automatic Liquid Filling Machine

Fully automatic liquid filling machine
Fully Automatic Liquid Filling Machine

Automatic liquid filling machine is systematically configured to perform its functions on its own without needing an operator.

Its source of power is electricity and is used in medium to large scale production due to its packaging efficiency.

 ProblemPotential CauseSolution
1Uneven Fills
  • Aged peristaltic pump.
  • Remove and replace worn-out tubing.
  • Confirm if peristaltic components are working well.
  • Swap non-functioning parts with functional components.
  • Verify machine configurations on the PLC touchscreen.
  • Adjust the settings accordingly.
2Displaced filling nozzle
  • Verify filling port spacing and height.
  • Modify the spacing and the height of the filling nozzle.
3Bottle movement issues.
  •  Inspect guide rails spacing on the conveyor belt.
  • Refine the conveyor belt tautness.
4Capping failure
  • Misaligned cap gripper, bottleneck finish, and star-wheel pockets.
  • Modify their position accordingly.
  • Inspect cylinder functionality.
  • Remove and repair or replace the damaged cylinder.
5Loose screw-on caps
  • Misaligned capper and star-wheel pocket.
  • Realigncapper with star-wheel.

Automatic liquid filling machine

Troubleshooting techniques are important for when liquid filling machine breakdown. However, it is important to realize preventing the faults from happening is equally necessary.

Performing preventive maintenance on your liquid filling machine will reduce the frequency of breakdown significantly. Here are tips you can follow for maintenance:

  1. Examine machine surrounding

When installing a liquid filling machine, ensure the environment its placed in is properly controlled.

Secondly, make sure you place it on a flat surface and away from high temperature and moisture.

  1. Assess the machine

It is good practice to inspect the machine for any damaged power cords, check power connection and electrical grounding before use.

Check and ensure all parts are functioning properly, then carry out a test run to verify the machine is working properly.

  1. Cleaning after a work shift

It is advisable to clean both the machine’s work surface and exterior after the work shift. A tank holding the liquid material is emptied and the nozzles are unclogged.

  1. Apply right tools

When cleaning, use a soft cloth with mild detergent to prevent eroding machine parts, and avoid sharp tools when cleaning machine surfaces.

  1. Lubricate moving parts

For proper functioning of moving parts, O-rings, seals, and grooves apply lubricants or oil on a regular basis.

  1. Clean regularly

Use alcohol to clean the stained machine frame and run the machine with warm water to clean the machine’s filling tube.

Disassemble machine parts and components that come into contact with filling material and clean them.

Blow out buildup dust from inaccessible places using compressed air.

  1. Schedule periodic maintenance

Inspect the machine’s exterior and working surfaces.

Tighten any loose components promptly check vulnerable parts and address faults immediately through repair and replacements.


To ensure your liquid filling machine stays in mint condition, it is important to learn troubleshooting skills as well as preventive maintenance tips. These tips should be taught to anyone who operates the liquid filling machine and followed to the latter.

More Resources:

Liquid Filling Machine Parts – Source: LOM

Choosing the Right Liquid Filling Machine – Source: LOM

How Liquid Filling Machine Works – Source: LOM

Applications of Liquid Filling Machine – Source: LOM

Liquid Fillers – Source: WIKIPEDIA

Update cookies preferences
Scroll to Top

Get a Quick Quote!