Liquid filling machine is an indispensable equipment in modern industrial production, widely used in food, beverage, chemical, pharmaceutical and other industries. Understanding the different types of filling machines and their characteristics is essential to improve production efficiency and ensure product quality.
In this blog, we will discuss a variety of filling machine working principles, scope of application and selection points, to help you make a wise choice of equipment.
Types of Liquid Filling Machines Based on Automation Level
Manual Liquid Filling Machines
Manual machines are the most basic type, which requires an operator to control the filling process.
| Advantages | Limitations |
| Low cost | Slow filling speed |
| Easy to operate | Inconsistent filling accuracy |
| Minimal maintenance | Operator fatigue |
Manual fillers are suitable for:
Small businesses with limited production needs
Products that require frequent changes in fill volume
Filling containers of various shapes and sizes
2. Semi-Automatic Liquid Filling Machines
Semi-automatic machines strike a perfect balance between manual operation and automation. They utilize pumps or pistons to dispense the liquid with precision.
3. Fully Automatic Liquid Filling Machines
Fully automatic machines are designed for high-volume production. They minimize human intervention and maximize efficiency.
Two common types of fully automatic fillers:
Inline filling systems
Containers move along a conveyor belt
Nozzles fill the containers as they pass by
Suitable for high-speed, continuous filling
Monobloc filling systems
Combines filling, capping, and labeling in one machine
Compact and space-saving design
Ideal for complete packaging solutions
Advantages of fully automatic machines for high-volume production:
High filling speeds (up to 600 containers per minute)
Excellent accuracy and consistency
Reduced labor costs
Minimized product waste and spillage
Automatic Liquid Filling Machine of Weijing
Wejing's fully automatic liquid filling machine is an advanced equipment widely used in the cosmetics, daily chemicals and other industries. It integrates a number of innovative technologies, such as programmable logic controller (PLC), human-machine interface (HMI) technology, imported high-precision electronic scales, etc., to achieve highly automated and precise filling operations.
The filling machine has high filling accuracy, up to ±1%. With multi-head parallel filling design, 316L stainless steel structure, hygienic and safe, humanized color touch screen interface, modular design, and flexible configuration, Wejing's fully automatic liquid filling machine represents the advanced level of liquid filling technology and is an ideal equipment for realizing production automation and improving product quality.
Types of Liquid Filling Machines Classified According to Filling Technology
In addition to being differentiated according to different levels of automation, filling machines can also be categorized based on their unique filling technologies. The main types include gravity fillers, piston fillers, pump fillers, overflow fillers, vacuum fillers, and net weight fillers.
1. Gravity Fillers
Gravity fillers rely on the fundamental principle of gravity to allow liquid to flow from an elevated tank into the container positioned below. The flow rate is precisely controlled by adjustable valves or nozzles, while the filling volume is determined either by a preset time or a level sensor that detects when the desired volume has been reached.
Advantages:
Simple design resulting in lower maintenance costs
Cost-effective solution for basic filling needs
Suitable for thin, free-flowing liquids
Limitations:
Applicable products:
Water, fruit juices, and thin sauces
Beverages, foodstuffs, and household chemicals
Main specifications:
2. Piston Fillers
Piston fillers employ a reciprocating piston mechanism to accurately measure and dispense liquids into containers. The piston draws the liquid into the cylinder during the upward stroke and then pushes it out into the container during the downward stroke. The volume of liquid dispensed is precisely controlled by adjusting the length of the piston stroke.
Advantages:
High precision dosing, even for viscous liquids
Handles a wide range of viscosities
Easily adjustable fill volume
Limitations:
Applicable products:
Sauces, creams, and pastes
Food, cosmetics, and pharmaceuticals
Main specifications:
Maintenance:
3. Pump Fillers
Pump fillers utilize various types of pumps, such as gear pumps, cam pumps, or peristaltic pumps, to transfer liquids from a tank into containers. The pump draws the liquid from the tank and pushes it through a nozzle into the container. The filling volume is accurately controlled by the number of pump rotations or by a preset filling time.
Advantages:
Versatility in handling a wide range of viscosities
Ability to achieve continuous, uninterrupted flow
Easy to clean and maintain
Limitations:
Applicable products:
Oils, shampoos, and liquid soaps
Personal care, automotive, and food & beverage industries
Main specifications:
4. Overflow Fillers
Overflow fillers are designed to ensure a consistent liquid level in each container, regardless of minor variations in container volume. The filling nozzle descends into the container and liquid flows until it reaches the level of an overflow pipe. Excess liquid is then returned to the main tank, maintaining a constant fill level.
Advantages:
Consistent fill level across all containers
Ideal for transparent containers where fill level is visible
Automatically compensates for variations in container capacity
Limitations:
Applicable products:
Beverages, cleaning products, and thin sauces
Beverage, household chemical, and foodstuff industries
Main specifications:
5. Vacuum Fillers
Vacuum fillers utilize negative pressure to gently draw the liquid into the container, making them ideal for filling foamy, delicate, or oxygen-sensitive products. The filling process begins by creating a vacuum inside the container, which then pulls the liquid in through the filling nozzle. The fill level is accurately controlled by releasing the vacuum at the appropriate time.
Advantages:
Minimizes product aeration and foaming
Gentle filling process for delicate or oxygen-sensitive products
Handles liquids with a tendency to foam
Limitations:
Applicable products:
Beer, carbonated beverages, and liquid medications
Beverage, pharmaceutical, and dairy industries
Main specifications:
Fiilling accuracy: ±0.5%
Speed: 30-150 containers per minute
Net Weight Fillers Net weight fillers use precision scales to ensure that each container is filled with the accurate weight of product. Containers are placed on the scale, and the filling process begins. The scale continuously monitors the weight of the container and its contents, stopping the fill at the precise target weight.
Advantages:
High accuracy in terms of product weight
Compensates for variations in liquid density
Ensures compliance with legal metrology requirements
Limitations:
Generally slower than volumetric filling methods Higher equipment costs due to the integration of precision scales
Applicable products:
Paints, chemicals, and foodstuffs
Chemical, paint, and coating industries
Specialized Liquid Filling Machines
1. Aseptic liquid filling machines
Aseptic liquid filling machines are designed to maintain an aseptic environment throughout the filling process, making them indispensable when packaging sensitive products such as pharmaceuticals and certain beverages. These machines utilize advanced technology to prevent contamination and ensure product safety.
The aseptic filling process of aseptic machines includes:
HEPA (High Efficiency Particulate Air) filtration system that removes 99.97% of airborne particles (down to 0.3 microns)
CIP (Cleaning-in-Place) and SIP (Sterilization-in-Place) systems that use a combination of heat, chemicals and high-pressure water to completely sterilize machine components
Laminar flow design creates a unidirectional airflow to prevent contaminants from entering the filling area
Key components of aseptic filling machines that help maintain sterility:
Aseptic valves with precision control and sterilizable design to prevent contamination during the filling process
Aseptic tanks with cleanable and sterilizable surfaces for storing the product under aseptic conditions prior to filling
Aseptic transfer systems, such as aseptic tubes and connectors, maintain the sterility of the product as it moves from the aseptic tank to the filling nozzle.
Aseptic filling machines are widely used in:
Pharmaceutical industry for filling injectable solutions such as vaccines, biologicals and liquid medications
Beverage industry for packaging of low acidic beverages (pH > 4.6) such as milk, plant-based milks and functional beverages that require extended shelf life without refrigeration.
The benefits of aseptic filling:
Producing shelf-life stable products without the need for preservatives and meeting consumer demand for clean-label products
Compliance with strict regulations set by organizations such as the FDA (Food and Drug Administration) and cGMP (Current Good Manufacturing Practices) ensures the highest standards of quality and safety.
2. Thermal Filling Machines
Hot fillers are designed to fill products at high temperatures, typically between 85°C and 95°C (185°F and 203°F). This process is particularly suitable for highly acidic foods and beverages, as the high temperatures help to sterilize the product and container, extending shelf life.
The hot-fill process includes:
Precise temperature control systems to maintain the desired filling temperature throughout the process, ensuring consistent product quality
Rapid cooling technologies, such as water baths or cooling tunnels, that quickly reduce the temperature of the filled container, preventing product spoilage and maintaining container integrity
Products that are typically filled using hot filling machines:
Highly acidic foods with a pH < 4.6, such as ketchup, salsa and pickles
Fruit juices, juice drinks and non-sparkling beverages containing natural preservatives such as citric acid.
Benefits and considerations of hot filling:
Extends product shelf life by reducing microbial growth, resulting in wider distribution and longer storage time
Heat-resistant packaging materials such as PET (polyethylene terephthalate) or glass are required to withstand high filling temperatures.
Modern hot filling machines often incorporate energy-efficient and sustainable designs, such as heat recovery systems and reduced water consumption, to minimize the impact on the environment.
3. Molten product filling machines
Molten product filling machines are machines specifically designed to handle products that are solid at room temperature but need to be filled in a molten state. These machines maintain the product at a precise temperature to ensure proper flow characteristics during the filling process and optimize the quality of the final product.
Unique features of molten product filling machines:
Precision temperature control system to maintain the desired molten state of the product, typically within a narrow range of ±1°C (±1.8°F)
Heated jacketed filling nozzles prevent premature solidification of the product during the filling process, ensuring accurate dosing and clean cut-offs
Temperature-controlled hopper with agitation system for storing molten product and maintaining uniformity prior to filling
Molten product filling machines are used in a variety of industries:
Cosmetic industry for filling lipsticks, solid perfumes and other wax-based products.
Food industry for filling chocolate, edible waxes and other confectionery products.
Quality control measures for the filling of molten products:
Continuous temperature monitoring at critical points such as hoppers, nozzles and product outlets to ensure consistency and prevent quality problems.
Optimal filling performance through precise temperature control and use of additives to adjust viscosity to achieve desired flow characteristics
This blog provides a comprehensive overview of the various types of liquid filling machines, categorized by degree of automation and filling technology, with detailed descriptions of each type's operating principle, range of applications and key features. As a leading provider of filling solutions, Wejing is the ideal partner to optimize your filling process with its expertise and commitment to customer satisfaction. Feel free to contact Wejing for more information.
