Whether you are a beginner or an advanced, everyone needs a perfect strategy to grow a business. Irrespective of your experience, you should know how to select an ideal machine. In addition, you must choose the suitable device for proper work art to your supply chain.
But you must be thinking, How do I make a perfect purchase?”
We are here to provide you with all the necessary and relevant information. In this article, you will learn how to buy a bottling machine. Looking at various manufacturers, we provide you with all in one place.
It is essential to know What are you going to fill. It will give us the roadmap to invest smartly in business. Because there are various types of machines comes into the purpose of packaging of supplying products. Includes different liquids like drinking water, petroleum jelly, perfumes and many more.
Selecting the proper machine will give an edge to fill these liquids into containers. But the main thing is that you can get the finished product effortlessly.
So, without getting your time wasted. Let’s dive directly to our discussed part
What is your filling?
When we talk about beverage bottle line, filling machines plays a significant role. The filling machine is an integral part of the beverage bottle line. Different bottle fillers are suited to fill other fillers like dry or liquid. Dry goods here imply powders and coffee, and liquid includes various drinks.
When we talk about liquids, lots of challenges come across. Because with drinks, viscosity plays an important factor. Depending on the low density and high viscosity, tasks vary. Let’s take a small example to illustrate how duties differ depending on the type of viscosity.
A machine(motor) that pumps out the water from the container will be known as low viscosity. And on the other hand, filling the jars of molasses would be known as high viscosity. As you can see, both of these are altogether two different tasks.
But this does not imply that there are only machines that either work with low viscosity or high viscosity. Instead, there exists a device that can handle both of them. And that’s why you need to ensure whatsoever machine you buy can have the ability to work with the product you’re bottling.
Check your product is Carbonated or not
You need to know that there are three common types of machines. These three types of filling machines are preferably used in the beverage industry. Includes
- Counter pressure fillers
- Flow volumetric filling machines
- Overflow filling machines
Now, if you are working or bottling with the carbonated product, you need a counter-pressure filler machine. These machines use to fill carbonated beverages(soda and beer). Different types of processes involved –
Carbonation: This process involves injecting the gas into a stream of water and adding it to the static liquid in a pressurized vessel.
Counter pressure fillings use for carbonated beverages.
What happens is the product is usually filled at a cool temperature to minimize the loss of CO2 during the process.
There are different functions on which this counter-pressure filler works. Some of them are listed below –
The first principle on which it works is that it removes the air from the bottle.
The second principle has done after the first. It is the process of pressurizing the bottle with CO2
After going through the above principles will now go with a doublepre-evacuation
It includes performing the above steps until the 99.9% removal of oxygen.
This process also involves filling the bottle with the carbonated product, precisely from the bottom of the product.
Requirement of the machine according to the bottle you are filling
It is advisable to purchase a suitable machine to work with specific containers. Fillers can fill many types of containers. One of the most basic mistakes that newcomers make is that they think one device can work with almost all containers. It is not like that. Specific machines are built to perform extremely good with the transparent container, while another machine can quickly destroy that container.
You will understand this concept with the proper example. You can think like that; some of the automated machines will have the potential to grab the bottle from the top. While in contrast to this, others can hold them from the sidewards. Think of this like this, if your bottle has the stabilized unique top, it most probably does not work with top-grabber. The same situation occurs if your bottle is too wide to handle, a side-grabber will not help in this case.
So, it is essential to know the parameter of the containers you are using. Then, you must consider what types of parameters I need to know for a perfect machine to buy. These include the size of the container you are using. Also, its height, diameter, as well as it’s shaped. These are the basic parameters that you need to check.
Automated machine selection for your business
Speed is the primary factor for differentiating between smaller machines and larger machines. We can find small appliances to measure the number of bottles they produce per hour. They are commonly known as BPH. On the other side of the road, large machines can identify by measuring bottles per minute. It is widely known as BPM.
Now, discussing some of the terms above, you can relate that a machine can vary from company to company. For example, a manual machine may be an excellent investment for a small company or brewing enthusiast, but it might not meet the demands of a giant or growing company. And this is one of the reasons to be sure**. So, how automated do you want your machine?**
As we see, a semi-automatic machine comes under a budget of less money to purchase, but also it’s not that big. So it will undoubtedly take a little more workforce to feed the bottles. Therefore if we see automatic machines, they will take surely ample space. But they help us reduce human resources, as they pull bottles from bulk with a conveyor system.
And that’s why we are providing you with a chart to help you with your desired speed and automation. With the help of this char, you can compare your requirements with machines.
Machines comparison for best results
After understanding lots of concepts, we are nowhere for comparisons. As discussed above, different machines perform quality results with other containers/products.
Are you looking for a Volumetric filling or Liquid Level machine?
- Volumetric filling: As the name suggests, the primary function of a volumetric filling machine is to fill the products by volume. Primary uses of this machine include filling liquids of different thicknesses, consisting of any foam or syrups.
The volumetric filling is responsible for filling the exact amount of liquid every time. These machines are costly. It is because of the requirements of the unique instruments for balance, timings, etc. These volume fillers are used explicitly in those industrial applications or laboratories where volume accuracy is the primary condition.
One of the most significant features of this machine is that they have reduced industrial wastages by a remarkable ratio. Moreover, this they have done with the function of “no bottle no filling system”. This system ensures the functioning of fillers halts when there is no bottle around for the filling in the machines. Hence, the volumetric filling has emerged as essential equipment in any industry.
- Liquid filling: If you are looking for uniformity, this is your final destination. This machine fills bottles, so they appear to be filled to the same line on every bottle. Because of this uniformity functioning, many companies, including cleaning products, beverages companies and many more, choose liquid level fillers.
These liquid fillers are very common in the beverage industry. Their primary work is for filling, which includes viscous and non-viscous liquids. And here comes the perfect role of liquid filler. It distributes the exact amount of liquid-based products.
It is essential to mention what type of container you will work with because this will consider our liquid filling machine.
Finding it challenging to select between overflow pressure ore gravity machine
- Overflow Pressure: This machine becomes the last choice for most beverage makers(wine, juice). It is used in consumer packaging applications where a consistent visual fill is required. When it comes to viscosity, these machines are shallow. But they produce great value to a business owner attempting to make bottles in bulk.
The product to be filled is held in a stainless steel reservoir. And in the next step, it is pumped into a manifold. To disperse the product to each of your filling nozzles. And in the last step, when the product reaches our desired cosmetic fill level in each bottle, excess product overflows back to the reservoir.
In the crux, we see the liquid entering the bottle fast under mentioned pressure. At the same time, the machine plays the role of catching spillage overflow and sending it back to the bulk source. These machines are built for various pressure pump speed control and ease of operation.
- Gravity machine: If you are looking for volumetric filling but cost-effective criteria. Then, my friend, this is where you need to stop. It is the most basic way of filling. It works on simple operations, which allows them to function with little maintenance. The supply tank is the central component of this machine.
These machines are built for various products, including beverages and chemical materials. You can use these machines in foamy products. But you hardly see anyone using these machines in bubbly products. Due to the fourth will rise beyond the liquid level in the bowl.
It is the most cost-effective form of filling machines. It works fantastic with acidic substances. These machines are considered best for filling free-flowing goods with a simple timer. They have this particular feature of dependence. In this feature, these machines can employ a range of filling nozzles depending on the product.
Unlike other overflow pieces of machinery, gravity filling machines do not use a recirculating mechanism and do not require specialized indicators. As a result, the gravity filler is a cost-friendly alternative for low densities and voluntary-flowing materials.
Are you confused in the selection between inline or rotary filling machines?
- Inline filling machines: Inline filling machines fill bottles just as they suggest, in a line. Inline engines are popular, cost-effective and easy to adjust to your needs. They can be made with four heads or 20 or more. Small to medium-sized companies often use inline-filling machines because if a problem occurs during production, the device can be stopped, fixed and put back into production faster than you can a rotary machine.
This also results in fewer bottles wasted. Inline machines are generally lower cost and require more minor size parts- more flexible for contract packagers. In addition, they offer easy accessibility for adjustment and maintenance. Rule of thumb- inline fillers are suitable for line speeds up to about 60-80/minute.
Containers have a stop/fill/start indexing motion, so twice as many heads do not double speed. A more extended nozzle bar causes longer index times.
- **Rotary filling machines:**Rotary filling machines are usually much more prominent, specialized machines that can have 25, 50, even 100 or more heads. Rotary machines are big, fast and will help your company produce far more BPM than your average inline machine.
However, if a problem occurs mid-production, many bottles are often wasted because there are many more in the machine at any given time. In addition, rotary machines can be complicated to fix, whereas inline engines tend to allow easier access to fix problems on the fly.
Rotary fillers offer a constant high container velocity (also preventing product spills and capper jams). For this reason, a rotary 8-head can be rated to 120 bottles/minute, and the same in 8 pumps used inline would only produce 80/minute (product dependent).
Customers using rotary fillers will have a higher production rate per foot of packaging floor space, but size parts get expensive.
I hope this overview article helped you understand how to buy a bottling line. If you feel this article can help others and fulfill their wishes, please share.
Or subscribe to the newsletter below for more insider tips on the beverage industry.