Abstract
As people's living standards continue to improve and material life becomes increasingly abundant, the packaging of Baijiu (a type of Chinese liquor) has also seen constant developments. Most Baijiu manufacturers have discovered unique-shaped bottles, cups and containers which have gained popularity due to their exquisite packaging and product characteristics. However, the filling equipment used for these unique-shaped bottles is not universal, which results in lower filling accuracy. This article analyzes the factors that affect filling accuracy and proposes solutions and ways to improve the filling accuracy of unique-shaped bottles by improving the filling machinery and providing relevant professionals and customers with valuable information for reference and exchange.
Keywords: packaging line; container; filling machine; container; packaging line;; irregularly shaped container; bottle; filling accuracy
In recent market years, almost all Baijiu manufacturers have been using various uniquely shaped bottles and containers to enhance the aesthetic appeal, packaging and variety of Baijiu. This process has significantly increased the sales power of Baijiu companies.
However, using non-standard filled bottles also makes it difficult for manufacturers to accurately control the filling line precision of white wine. Even if some manufacturers have designed filling equipment for non-standard filled bottles, not all non-standard filled bottles are universal. When a different product is used, there may be errors in the filling lines precision of the company using non-standard bottle filling equipment.
Additionally, companies invest a lot due to the high cost of specialized bottle-filling systems and cleaning equipment, but the impact is minimal or not significant enough to provide customers with a good return on investment. As a result, the production cost of liquor manufacturers is significantly increased, and the quality of filling and cleaning, may need to be more effectively guaranteed, which may lead to consumer dissatisfaction and significantly reduce the company's competitiveness.
1 Factors that Affect Filling Accuracy in Liquor Bottling Machine
The following formulations and numeric table provide additional information about the number of factors, equipment and control systems that affect filling lines accuracy in liquor bottling systems:
Constant Liquid Level in Filling Machine:
Maintaining a constant liquid level in the filling machine system ensures a stable pressure that affects the machines' filling accuracy and efficiency. If the fluid level is too high, overfilling can occur; if it's too low, underfilling can occur. To maintain the correct liquid level, it is essential to:
- Monitor the liquid level in the filling machine regularly
- Adjust the valve or pump speed to maintain a consistent level
- Periodically check the rubber seals and gaskets to ensure that they do not cause any leaks.
Consistent Filling Machine Speed:
A consistent and efficient filling machine speed is critical to filling accuracy. The container of liquor may splash if the speed of piston fillers is too slow, leading to overfilling. If the speed of fill it is too fast, underfilling can occur, resulting in less alcohol content. To maintain the correct speed, it is essential to:
- Continuously monitor the machine's speed to ensure it is consistent
- Adjust the settings if necessary to achieve the desired speed
- Conduct regular maintenance checks on the filling machines to prevent any unexpected variations.
Cleanliness of Volume Cup:
The cleanliness of the fill volume cup is essential to filling accuracy, as any impurities, liquids or residues can affect the accuracy of the fill measurement. To maintain the cleanliness of liquids in the fill volume cup, it is necessary to:
- Clean and sanitize the volume cup regularly using approved procedures
- Ensure that the volume cup is free of any water or residue before use
- Store the volume cup in a clean and dry place.
The precision of Volume Cup:
The precision and shape of the volume cup significantly affects filling accuracy. Any defects, misalignments, or incorrect measurements in the volume cup can lead to inaccurate liquor dispensing into the bottles. To maintain the precision and shape of the volume cup, it is essential to:
- Regularly check the volume cup for any defects or misalignments
- Replace the volume cup if it is damaged or worn out
- Use only calibrated volume cups that meet product quality standards.
Avoiding Liquor Flow Instabilities:
Liquor containers with flow instabilities, such as splashing liquids or frothing liquids, can significantly affect filling accuracy. To avoid liquor containers with flow instabilities, it is essential to:
- Use a filling machine appropriate for the product being bottled
- Ensure that the product temperature is suitable for filling conditions
- Take proper measures to stabilize the liquor if needed.
Maintaining filling accuracy in liquor solution bottling systems is an important aspect and essential to ensure product quality and customer satisfaction. Consistent liquid levels, filling machine speeds, clean and precise volume cups and avoiding liquor solution flow instabilities are primary factors that affect filling accuracy that must be reviewed and optimized. Regular maintenance checks and quality control measures can minimize the impact of these factors and keep the solution filling accuracy within acceptable limits.
2 Improving Filling Accuracy of Filling Machines
Filling machines are widely used in the food and beverage industry to meet the increasing demand for beverages such as wine, soda, and fruit juice. However, the accuracy of filling machines can vary based on factors such as the machine's design, the operator of machinery's skill level, and product viscosity. Therefore, it's crucial to take steps to improve the accuracy and product viscosity of the filling machinery. In the first step of this article, we'll discuss some ways to enhance filling machinery' accuracy.
Installing a Fixed Bracket
Installing a suitable fixed bracket system can significantly improve the filling accuracy of a filling and other machines too. A specified frame can be manufactured to adjust the upper and lower valve ports with the help of the filling machine's cam. Before installing the bracket, the sealing gasket and bottle holder should be removed. The upper part of the bracket should be in the same direction as the guiding rod, and the nut should be tightened to make the installation firm. When using a fixed bracket system, it's essential to ensure that all brackets in the filling machine are of the same size and shape to achieve consistent and accurate filling.
Using Transparent Plastic Tubes
Installing a tee can help stabilize the liquid level and allow direct observation of the liquid level's position during production process. To establish a tee, one end should be connected to the liquid supply line, and the other end should be led to the elbow. A transparent plastic tube should be installed on the comprehensive surface to view the liquid level clearly. The liquid level's position can be observed directly by utilizing the connectivity principles, making the filling machine and process more convenient, simple, efficient and precise.
Installing Guide Tubes
The tube's size and shape should be determined based on the bottle's neck size when installing guide tubes. The size selection criteria are that the minimum outer radius of the guide tube should be kept at least 0.5cm away from the minimum inner radius of the bottleneck. This requirement is necessary to prevent air bubbles from causing errors in the filling and cleaning process. Choosing guide valves and tubes that are non-toxic and meet the standard hardness criteria is crucial. Using a guide tube with adequate hardness could prevent it from becoming soft during filling, making accurate filling impossible.
In conclusion, the accuracy and performance of a filling machine is critical to maintaining a production line's efficiency, reduced costs, and ensuring customer satisfaction. Installing guide, stainless steel tubes, transparent plastic tubes, and fixed brackets can significantly down costs and enhance filling accuracy. Attention must be paid to ensure that the size and hardness of the equipment meet appropriate standards to achieve optimal performance. By following these steps, manufacturers can improve filling accuracy and avoid costly production line errors.
Numeric Data Table
| Method | Advantages | Disadvantages |
|---|---|---|
| Installing a Fixed Bracket | More accurate filling | Requires customized bracket |
| Using Transparent Plastic Tubes | Direct observation of liquid level | Only suitable for certain products |
| Installing Guide Tubes | Prevents air bubbles | Requires matching tube size and hardness |
3 Conclusion
As people's living standards improve, they have a growing demand for beautifully-crafted goods, leading to the rise of uniquely-shaped bottles. Different manufacturers have produced a variety of shapes, which the market has responded positively to. However, using to fill these bottles presents some challenges with filling accuracy, which has led to significant advancements in filling machine technology. Despite the complexity and costs of filling these bottles, it has stimulated the development of the liquor industry and increased consumer preference for creatively-shaped bottles. Improving filling accuracy is essential to gain consumer approval, so investing sufficient funds in this area can make significant savings for customers and make white liquor companies more promising.
To achieve optimal filling accuracy, manufacturers should consider installing a fixed bracket, transparent plastic tubes, and guide tubes. By following the aforementioned steps and selecting appropriate equipment sizes and hardnesses, manufacturers can improve filling accuracy. iBottling is an experienced and reliable supplier of beverage filling solutions and packaging machines solutions that has been providing high-quality products since its founding in 2005. Contact us today to discuss your production needs and get access to our full line of cutting-edge solutions for better bottle filling and packaging accuracy.
Reference:
FENG Ya, SHEN Haibin, YING Weina. Applying Six Sigma tools to improve the bottle explosion rate in the production, packaging and cleaning process of lyophilized powder syringes . Shanghai Medicine, 2019(13).
Shanghai Dongfulong Intelligent Control Technology Co., Ltd. Case study of the integrated multifunctional packaging line pre-sealing filling lines system, certified by EUGMP . China Pharmaceutical Industry Journal, 2016(9).
