Weight Filling Machine – The Ultimate Guide

A weight filling machine is a special-purpose system designed to inject precise volumes of products into containers based on their pre-established weight.

Thanks to today’s high-end weighing technology, these machines can dispense spot-on capacities of your goods thus elevating your brand’s reputation.

Technologies Used to Dispense Products in Weight-Filling Systems

Weight Filling Machine
Weight Filling Machine

Depending on the type of product being dispensed, your net weight filler can exploit either of the following dispensing technologies:

  • Gravity Discharge: This is one of the simplest and most reliable filling technologies. It utilizes gravity to feed your product into a weighing bucket for measurement and ultimately into your respective containers. It is however limited to free-flowing liquid products.
  • Vibrating Tray Method: This is a technology that is highly prevalent in weight-filling machines designed to dispense granular goods and powders. Fillers utilizing this method come with a vibrating tray installed underneath the weight bucket.
  • Pneumatic Filling: This is an advanced dispending technology on compressed air pushing. As such, it tends to guarantee more accurate discharging. Pneumatic filling is however limited to dispensing powdery products, where it offers faster dispensing rates.
  • Auger Screw Technique: The auger screw filling technique relies on a rotating screw conveyor to deliver precise measurements of your product into your containers. This technology is heavily utilized due to its consistent filling and gentleness hence it is applied to dispense granular goods.
Net Weight Filler Working Principle
Net Weight Filler Working Principle

Benefits of Using Weight-Filling Machines

Specially built to utilize weight as a measurement for accurate product filling, weight-filling machines pack a myriad of distinct advantages.

  • Accuracy: By relying on high-end measurement and dispensing technologies, these machines guarantee you a perfect filling experience. This eliminates the risk of inconsistent product weights.
  • Speed: Owing to technologies like pneumatic filling, you can achieve an astronomical production output since you will fill more containers.
  • Efficiency: Weight fillers shrink the chances of dispensing surplus products thus minimizing wastage. They also eliminate the risk of spillage.
  • Reduced Labor: Contemporary weight fillers are highly automated and this eradicates the need for tedious and costly human labor.
  • Data Collection: Automated weight fillers collect essential data such as the number of containers filled and their respective weight measurements.
  • Improved Hygiene: These systems can handle sensitive products such as edible oils or other foods without risking contamination.
  • Improved Compliance: Thanks to their precise discharging, you are guaranteed to comply with weight or volume requirements.
  • Diversity: Weight-filling machines can be altered to accommodate varying products thus allowing you to package goods of varying nature.
  • Adaptive to Different Container Sizes: You can change the output nozzles of your weight filler to ensure they are compatible with varying container sizes.
  • Real-Time Monitoring: They feature modern control boards that incorporate advanced tracking features. You can remotely reset discharge levels.

Main Parts of Weight Filling Systems

To accurately feed your products into their respective containers, your net weight dispensing machine relies on multiple components. It is the unification of these components that lays the foundation for precise product packaging.

· Hopper

This is essentially a product holding tank tasked with stocking your bulk product before it is measured and dispensed into your containers. It is essentially a large tank that may come in distinct designs. Its design and construction material determine the kind of products it can handle.

· Feeder

The feeder is a discharging system responsible for transferring your products from the hopper to the weigh bucket before filling into the container. Net weight filling systems come with varying types of feeders but the most popular options include:

  • Vibratory Feeders: These feeding systems rely on vibration to unfasten your product and feed it into your respective jars.
  • Auger Feeders: These feeding systems are utilized in weight fillers with rotating screw conveyors. This makes them perfect for moderately lightweight goods such as cereals.
  • Screw Feeders: Screw feeding systems are centered on rotating screw conveyors but are quite more productive than auger feeders. They are primarily designed to discharge viscous products.
  • Belt Feeding Systems: These discharging systems rely on a belt to transfer large products from the hopper to your weigh bucket and packaging containers. They are also ideal for products with asymmetrical designs or shapes.
Weight Filling Machine Parts
Weight Filling Machine Parts

· Weigh Bucket

Since weight dispensing systems utilize weight to determine precise product measurements, they come with a weighing component. This component features an extremely responsive load cell that captures the product’s weight and relays this data to your control board. This load cell is linked to a bucket hence the name weigh bucket.

· Discharge Mechanism

The discharge mechanism may come in distinct forms with nozzles or valves being the primary discharge components. These components regulate the volume of products being transferred into your packaging containers. They can exploit distinct technologies such as gravity, pneumatics, or servo-mechanism.

· Conveyor Belt

The conveyor belt is a moving band responsible for carrying your packaged container from the filler’s weigh bucket to a capping machine. You can set the conveyor belt speed from your filling machine’s control board.

· Control Board

In most contemporary weight-discharging machines, the control board is a programmable system with a user-friendly interface. You can set the weight threshold, the conveyor belt speed, and the filling level from this board. This control system also comes with monitoring features, which allow you to keep watch on your filler’s performance.

Working Principles of Net Weight Filling Machines

Net weight filling machines give you accurately packaged products but to achieve this feat, they undertake numerous steps.

Underneath, we break down these steps to give you an understanding of how your weight filler operates.

Step 1: Product Loading

To kickstart the filling process, a certain product, let us say edible oil is injected into a hopper in bulk. This giant container will hold your bulk supply as it awaits measured dispensing. Your filler’s hopper may vary in design depending on the type of product being packaged.

Step 2: Product Injection

After your bulk product has been loaded into the weigh filler’s hopper, it is then dispensed into a weigh bucket via valves. This bucket relies on load cells that are immensely sensitive to measure the weight of your product.

Step 3: Product Measurement

Once your product hits the weight bucket, its real-time weight is measured and the resulting value is sent to your controller. Since the controller has a predetermined weight set, dispensing of the said product is halted once this value is hit.

Step 4: Product Filling

After the said product has been precisely measured and its predetermined weight value reached, filling commences. The filling process is initiated by the filler’s control computer and it sees your product fed into a bottle, bag, or any other container type.

Step 5: Packaging Container Removal

With your product accurately packaged in your container, it is time to remove this packaged container to create space for more containers. This is undertaken by a conveyor belt, which takes your container to the next step, which may include capping.

Types of Weight-Filling Machines

Weight is an attribute that can be utilized as a parameter to correctly and accurately fill containers with distinct products. As such, numerous kinds of weight-based filling machines have been invented. Here are the most prominent options:

Automatic Weight Filling Machines

Automatic weight fillers are product discharging equipment designed to minimize manual packaging. The filling processes, starting with bulk product loading and ending with capping are undertaken by automated machines. They feature highly responsive sensors, which give them an unrivaled accuracy profile.

Automatic Weight Filling Machine
Automatic Weight Filling Machine

Semi-Automatic Weight Filling Machines

Semi-automatic weight fillers attempt to marry the positive features of human packaging with those of automatic filling. In most semi-automatic fillers, the filling process is automated while container placement is non-automated. This, however, limits their application to relatively small-sized manufacturing processes.

Semi Automatic Weight Filling Machine
Semi-Automatic Weight Filling Machine

Gravity Net Weight Fillers

These weight-filling machines are distinguished by the unique technology they employ to dispense your products into your containers. They utilize gravity hence they come fitted with gravity feeders for discharging your fluid to the weigh bucket. Gravity-weight filling machines are prominent in food and beverage packaging.

Gravity Net Weight Filler
Gravity Net Weight Filler

Multi-Head Weight Filling Systems

Characterized by more than one filling component, multi-head weight fillers are engineered to support large-scale packaging operations. The availability of multiple discharging components means that you can fill multiple containers simultaneously. As such, they are greatly revered in industries such as edible and motor oil manufacturing industries.

Multi Head Weight Filling Machine
Multi-Head Weight Filling Machine

Auger Weight Filling Machines

Auger weight fillers primarily inject granulated or powder products into containers with utmost accuracy. This high level of precision is achieved thanks to the filling technology they utilize. They depend on rotating screw conveyors, which optimize their filling speeds and filling accuracy.

Auger Weight Filling Machine
Auger Weight Filling Machine

Piston Net Weight Filling Systems

These weight-filling systems have their filling operation centered on the use of pistons. They employ the piston mechanism to transfer your products, specifically viscous liquids to the weigh bucket. Piston weight fillers are extremely accurate hence they are widely utilized to package medicine and cosmetic products.

Piston Net Weight Filling Machine
Piston Net Weight Filling Machine

Linear Weight Filling Machines

Named after the sequential fashion in which they discharge products into jars, linear weight fillers are tremendously revered. They are comparatively flexible and scalable, meaning they can easily accommodate differently sized or designed containers. They are highly popular in chemical filling and cosmetic product packaging.

Linear Weight Filling Machine
Linear Weight Filling Machine

Why Accurate Weight Filling is So Important

The significance of delivering precisely weighed consumer products like washing powder cannot be underplayed. Precise weight-based filling results in consistent product volumes thus bolstering your reputation as a trustworthy and reliable brand.

  • Positive Brand Reputation: The pinpoint accuracy of weight-filling machines is mirrored in the respective weight accuracy of your packaged products. This builds you a well reputable brand.
  • Product Consistency: Filling your containers with appropriate amounts of your product results in a consistent product weight. This eliminates variations in product capacity.
  • Minimized Waste: Having your products accurately packaged also saves you unnecessary losses by averting excessive product volumes.
  • Cost-Saving: Accurate filling also comes with financial benefits. Exploiting the precision of net weight fillers helps you achieve this by mitigating spillage and over-packaging.
  • Dosage Accuracy: Certain products such as syrup medication necessitate accuracy during dispensing to avert incorrect dosages. With a medicine weight filler, you are guaranteed precise dosages.
  • Regulatory Compliance: Selling products with inaccurate weight measurements can land you in trouble. This underlines the need for accurate filling.

Maintaining Your Net Weight Filling System

Deprived of meticulous care and maintenance, your net weight dispensing system is likely to lose its precision or break down prematurely. This underscores the significance of appropriate maintenance and here are the best care practices you should follow.

  • Frequent Cleaning: Once you are done filling your product, you should shut down the weight filler and then proceed to clean it. This will dislodge your product residue and any accumulated dirt thus ensuring you conform to applicable hygiene standards.
  • Frequent Inspection: Carry out scheduled inspections on time to ensure that your filler is in tip-top condition. During your inspection check for any signs of wear or fault in your essential components.
  • Lubricate Mechanical Components: This applies to the moving parts found in your weight-filling machine. For example, frequently lubricating the bearings on your conveyor belt will avert friction, which can mess up your filler’s filling speed.
  • Update Your Software: Advanced weight fillers utilize PLC control boards that run on specific software. Once you are notified that there is a software update, ensure that you install it in your control system.
  • Tighten Your Nuts: Continued use can result in loose bolts or nuts. This can be a safety hazard thus it is recommended that you regularly check your filler for loose bolts. Additionally, ensure that all parts are properly aligned and connected.

Common Applications of Weight Fillers

Manufacturing industries and entities looking to optimize outputs and minimize production costs are turning to weight fillers. These indispensable units are currently aiding a myriad of industries and businesses to adhere to weight requirements.

  • Oil Filling: Manufacturers of oil, both edible and motor oil are huge beneficiaries of net weight fillers.
  • Milk and Yoghurt Filling: Dairy products industries utilize weight fillers to package accurate volumes of milk and other dairy products.
  • Detergents Filling: In the detergents industry, weight-filling machines are widely employed to dispense powder detergents, washing gels, and liquid detergents.
  • Chemical Filling: There are specially crafted weight fillers designed for filling chemicals into respective containers. These fillers are treated to withstand chemical reactions.
  • Sauces and Dressings: Ultra-clean weight fillers are designed to hastily package distinct food elements like sauce and other flavorings without risking contamination.
  • Cosmetics Filling: Weight fillers also help personal product manufacturers dispense accurate volumes of lotions and other cosmetic products efficiently.
  • Paints Filling: In paint manufacturing, they are vastly exploited to package liquid paint and coatings into containers of varying sizes.

At LOM, we design highly efficient weight fillers depending on your unique requirements and specifications.

For all your custom machines from China, contact us now.

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