What is Volumetric Bottle Filler – The Ultimate Guide

A volumetric bottle filler is an elaborate system designed to bottle pre-programmed volumes of liquid or powdery products. This machine measures the capacity of the product being bottled thereby guaranteeing you precise filling.

Types of Volumetric Bottle Fillers

Volumetric Bottle Filler
Volumetric Bottle Filler

Manufacturing industries currently reliant on bottle-filling machines bottle varying products and have distinct requirements. To gratify the distinct demands of these industries, varying forms of volumetric bottle fillers have been introduced.

Volumetric Piston Bottle Fillers

Volumetric piston bottle fillers are characterized by the piston technology they exploit to inject accurate volumes of your product into bottles. They feature numerous pistons, whose controlled movement initiates the dispensing of liquids into bottles. They are revered across multiple industries thanks to their compatibility with different products.

Volumetric Piston Bottle Filler
Volumetric Piston Bottle Filler

Volumetric Pump Filling Machines

These volumetric bottle fillers rely on gear or rotary lobe pumps to transfer measured volumes of product from bulk tanks to your bottles. Their working principle, the positive displacement process, guarantees you precise and uniform fill rates and levels. They are prominently utilized to bottle beverages, cosmetics, and pharmaceutical products.

volumetric pump filling machine structure and its working principle
Volumetric Pump Filling Machine Structure and Its Working Principle

Volumetric Flow Meter Bottle Filling Machines

Volumetric flow meter fillers reward you with an accurate fill rate and level by utilizing advanced flow meters. These meters are connected to a control board programmed with the appropriate flow rate and level. Once the desired fill level is achieved, the control board instructs the flow meter to halt the flow.

Volumetric Flow Meter Bottle Filling Machine
Volumetric Flow Meter Bottle Filling Machine

Volumetric Gravity Fed Fillers

These volumetric bottle fillers are known for their simplistic operating principle, which is centered on gravity. They feature valves or nozzles equipped with level sensors or timers to regulate your fill volume. Once a preprogrammed fill level is achieved, the sensors instruct the automatic valves to close.

volumetric Gravity Fed Filler Structure and Its Working principle
Volumetric gravity Fed Filler Structure and Its Working principle

Volumetric Overflow Bottle Fillers

Overflow bottle fillers fill your bottles to the brim before redirecting the surplus product back to the bulk holding tanks. This ensures a consistent fill rate since all your bottles are filled. These filling machines are commonly exploited to package sauces, flavorings, and dressings.

Volumetric Overflow Bottle Filler
Volumetric Overflow Bottle Filler

Net-Weight Volumetric Bottle Fillers

Net-weight volumetric bottle-filling machines are advanced fillers combining two principles to ensure optimal accuracy levels. These machines primarily rely on volumetric aspects to dispense products into your bottles. However, they also utilize weight parameters to guarantee a uniform and precise fill rate.

Net Weight Volumetric Bottle Filler Structure
Net Weight Volumetric Bottle Filler Structure

Essential Parts of a Volumetric Bottle Filler

Volumetric bottle fillers are essentially multi-purpose systems designed to serve several roles. To satisfactorily fulfill these roles, they are endowed with multiple components, each customized to serve a different role.

Container Handling System

This is essentially the feed system, which is made up of high-volume tanks specialized to hold your bulk product before bottling. This is also referred to as the hopper and it may come in varying capacities or designs. The handling system is also fitted with dispensing components like rotary lobe pumps.

Dosing System

The dosing system is linked to filling nozzles and is tasked with dictating the volume of product each nozzle injects into your bottles. Contemporary volumetric fillers are endowed with automatic dosing systems and this guarantees you a steady product volume. Common dosing systems installed in volumetric fillers include flow meters, timers, and level sensors.

Filling Nozzles

Filling nozzles are spouts attached to small tubes and tasked with transferring your product from the bulk reservoir into your respective bottles. Their opening and closing are meticulously controlled by your filler’s control system and this results in precise fill levels. They come in varying designs including;

  • Spring-loaded nozzles.
  • Diving nozzles.
  • Anti-drip nozzles.

Conveyor System

Filled bottles must be transported to the capping system and the labeling machine. This is typically accomplished with the help of conveyors. These conveyors are also crucial in moving empty bottles to their respective filling areas.

You can adjust the layout and speed of your filler’s conveyor depending on your production demand. Common conveyor systems include belt conveyors and slat conveyors, which are available in unique designs like rotary, straight, and indexing.

Capping System

Once your bottles have been filled, they must be sealed instantly to avert contamination and spillage. This is why most volumetric bottle fillers come with an integrated capping system. The filled bottles are transported to the capping system using conveyors before being tightly sealed.

Controller

The controller is the chief operating component tasked with controlling and coordinating the operation of the other components. Most controllers on modern volumetric bottle fillers are computerized and can support remote monitoring.

Volumetric Bottle Filler Features

  • Automatic Bottle Handling: These fillers utilize automatic control systems, conveyors, and dispensing nozzles thereby minimizing the need for human input.
  • Multiple Filling Nozzles: Volumetric fillers come equipped with several filling nozzles thus allowing you to fill multiple bottles simultaneously.
  • Overflow System: They also have an overflow system, which ensures that the excess product is reinjected into the reservoir thereby minimizing wastage.
  • High Precision: Volumetric bottle fillers rely on proven dispensing technologies like pistons and flow meters and this translates into precise filling.
  • Adjustable Filling Volumes: using the control board, you can adjust the fill level and other specifications. You can also modify the filling nozzles to accommodate differently sized or designed bottles.

How a Volumetric Bottle Filler Works

  • Bottle Placement: First, the containers to be bottled are strategically and carefully arranged on a conveyor system. This conveyor system then transports the bottles to their respective filling stations, placing one bottle per nozzle.
  • Bottle Centering: Once the bottles arrive at their respective filling stations, they are carefully positioned beneath the respective nozzles. This averts spillage which can lead to losses and pose a contamination risk.
  • Filling: With the bottles centrally positioned, the filling process is initiated. In automatic volumetric fillers, the filling nozzles are instructed to open by a pre-programmed control board. Once the pre-determined fill volume is attained, these valves or nozzles close down automatically.
  • Volume Adjustment: To ensure that your volumetric demands are adequately met and uniform across all your bottles, the fil level is adjusted. This is accomplished with the help of level sensors and overflow monitors.
  • Container Exit: Once the perfect volumetric level is attained, the filled bottles are seamlessly ejected from the filling station. In most volumetric fillers, they are moved to the capping machine by a conveyor belt.
  • Capping: The majority of high-level volumetric bottle fillers come with integrated capping units. Once the bottles are delivered at the capping station, they are tightly sealed to mitigate spilling and contamination.

Why You Should Use a Volumetric Bottle-Filling Machine

By focusing on the volumetric metric of bottle filling, volumetric bottle fillers manage to achieve unrivaled precision degrees. Their use can be beneficial to you in several ways:

  • Precise Measurements: A volumetric bottle filler will ensure that your bottle’s volume is not higher or lower. The volume of your product is guaranteed to be precise.
  • Volume Consistency: Forget about uneven fill levels thanks to volumetric bottle fillers. These systems fill your bottles with the exact same volume of product at all times.
  • Increased Production: With a volumetric filler, you can bottle multiple containers instantaneously thanks to their multiple nozzle configuration.
  • No Room for Human Error: Human input, although reliable, comes with inconsistencies which can be costly. However, using a volumetric filler eliminates these variations resulting in consistent and accurate fill levels.
  • Reduced Downtime: Volumetric bottle fillers can operate continually without deteriorating production levels. The same cannot be said about manual bottle filling.
  • Versatility: You can use volumetric fillers to dispense distinct types of products into bottles. You can also use them to fill distinctly sized and shaped containers.

Limitations of Volumetric Bottle Fillers

Volumetric bottle dispensing machines are undoubtedly highly beneficial systems, particularly in manufacturing industries. However, their utilization comes with a few limitations, which are luckily, not a deal breaker.

  • Viscosity Limitations: When filling liquid products with extremely high viscosities, the accuracy of volumetric bottle fillers drops. This can lead to uneven fill volumes in your bottled products.
  • Inability to Handle Foaming Liquid: If used to dispense foaming fluids like beer into bottles, the fill volumes attained may differ. This results in inconsistent fill levels, which can harm your brand’s reputation.

Present-Day Applications of Volumetric Bottle Filling Machines

  • Soft Drink Bottling: Volumetric fillers are widely used to bottle energy drinks and other soft drinks thanks to their ability to handle foamy products.
  • Water Bottling: Their ability to fill multiple bottles of water simultaneously while attaining precise fill volumes advocates for their use in mineral water bottling.
  • Juice Bottling: Volumetric fillers are capable of handling liquids with varying viscosities and this has driven their use in bottling different types of juices.
  • Personal Care Products Bottling: In the personal care industry, they are broadly exploited to dispense accurate volumes of lotions and shampoos into packaging containers.
  • Syrup Medication Bottling: Volumetric bottle fillers come in handy in the pharmaceutical industry where they are utilized to bottle liquid medications.

Additional Applications

  • Motor oil bottling
  • Alcohol bottling
  • Flavorings bottling
  • Paint filling
  • Liquid soap bottling
  • Milk bottling
  • Cooking oil bottling
  • Chemicals bottling
  • Lubricants bottling
  • Honey bottling

More Resources:

Volumetric vs Liquid Filling Machines – Source: LOM

How Volumetric Filling Machine Works – Source: LOM

What is Volumetric Filler – Source: LOM

Filling Machine – Source: LOM

 

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