Tube filling and sealing machines are automated systems essential for packaging products in tubes across pharmaceutical, cosmetic, and food industries. These machines ensure precise filling, secure sealing, and high production efficiency, transforming manual operations into automated processes.
In this comprehensive blog, we'll explore the fundamentals, technologies, and best practices of tube filling and sealing machines.
Understanding Tube Filling and Sealing
What is tube filling?
Tube filling is the process of dispensing a specific volume of product into a tube container. This process is commonly used for packaging semi-solid or viscous products, such as toothpaste, creams, gels, and ointments. The filling process must be precise to ensure that each tube contains the correct amount of product, as specified by the manufacturer.
What is tube sealing?
Once the tube is filled with the desired product, it must be sealed to maintain product integrity and extend its shelf life. Tube sealing involves closing the open end of the tube, creating an airtight and tamper-evident seal. Proper sealing is essential to prevent product contamination, leakage, and deterioration, which can negatively impact the quality and safety of the product.
Fundamentals of Tube Filling Technology
Core Technologies
Modern tube filling machines employ various filling technologies, each suited to specific applications:
Volumetric Filling Systems
Utilize precision-engineered pistons or pumps
Accuracy typically ranges from ±0.5% to ±1%
Ideal for products with consistent viscosity
Common in pharmaceutical applications
Fill volumes from 5ml to 300ml
Time-Pressure Filling Systems
Based on constant pressure and timed dispensing
Best suited for low-viscosity products
Cost-effective solution for simple applications
Fill accuracy around ±1-2%
Requires stable product viscosity
Net Weight Filling Systems
Uses load cells for real-time weight monitoring
Highest accuracy (±0.2% or better)
Ideal for products sold by weight
Independent of product density changes
Integrated feedback control loops
Flow Meter Technologies
Electromagnetic or Coriolis flow meters
Excellent for continuous production
Real-time flow monitoring and adjustment
Suitable for various viscosities
Easy integration with control systems
Hot Fill Systems
Temperature-controlled filling (up to 95°C)
Specialized for heat-sensitive products
Integrated cooling systems
Enhanced product stability
Required for certain food products
Precision Control Methods
Maintaining precise control over the filling process requires several integrated systems:
Temperature Control Systems
PID-controlled heating/cooling circuits
Temperature accuracy ±0.5°C
Product temperature monitoring
Jacketed product tanks
Heat exchangers for rapid temperature adjustment
Pressure Regulation Mechanisms
Electronic pressure regulators
Pressure range 0.5-6 bar
Real-time pressure monitoring
Automated pressure compensation
Anti-surge protection
Flow Rate Management
Servo-driven pump systems
Variable frequency drives
Flow rates from 1ml/min to 100L/min
Dynamic flow adjustment
Closed-loop control systems
Components and functions of tube filling and sealing machine
Feeding part:
There are hose feeding device and hose positioning device. The feeding device automatically transports the bulk hose to the filling position, and the positioning device accurately positions the hose to prepare for subsequent filling.
Filling part:
The filling part covers filling pump, filling valve, filling nozzle, etc. The filling pump transports the material to be filled to the filling valve, and then accurately injects it into the inner cavity of the hose through the filling nozzle. Common filling methods include piston pump filling, gear pump filling, etc.
Sealing part:
The Sealing part includes hot pressing device and cooling device. The hot pressing device heats and presses the tail of the hose by heating the seal to make it firmly sealed; the cooling device quickly cools the seal after hot pressing to ensure the sealing quality.
Coding part:
It concists of coding device, which can print production information such as production batch number and date on the surface of the hose to facilitate product traceability.
Output part:
It is composed of conveyor belt and collection device. The filled hoses are output in order through the conveyor belt, and the collection device collects them together to complete the entire filling and sealing process.
Control part:
It consists of a PLC control system and a human-machine interface. The PLC control system is the core of the equipment, coordinating the actions of various components to achieve automatic control; the human-machine interface facilitates operators to set parameters, monitor status, etc.
Types of tube filling and sealing machines
Tube filling and sealing machines come in various configurations to suit different production requirements:
Semi-automatic machines: These machines require some manual intervention, such as loading empty tubes or initiating the filling and sealing process. Semi-automatic machines are suitable for small-scale production or low-volume runs.
Fully automatic machines: Designed for high-volume production, fully automatic machines handle the entire filling and sealing process without manual intervention. These machines offer the highest levels of efficiency and consistency.
Rotary machines: Rotary tube filling and sealing machines arrange tubes on a rotating turret, allowing for continuous filling and sealing operations. These machines are ideal for high-speed production and can handle large volumes of tubes efficiently.
Linear machines: Linear machines arrange tubes in a straight line, with filling and sealing stations positioned along the production path. These machines offer flexibility in terms of tube sizes and are suitable for medium to high-volume production.
How to select the Right Tube Filling and Sealing Machine for Your Needs
Choosing the right tube filling and sealing machine is essential for manufacturers to ensure optimal production efficiency and product quality. Here are some basic factors to consider when choosing a machine:
Production requirements
It is important to consider your production requirements to ensure that the machine can meet your current and future needs. Capacity, tube specifications, and product characteristics need to be evaluated before making a selection.
Capacity
Determine your production volume requirements, including current needs and future growth. Consider the following:
Tubes per minute (TPM): Look for a machine that can achieve the required output rate to meet your production goals. High-volume manufacturers should choose machines with higher TPM capabilities.
Shift pattern: Evaluate your shift pattern and the number of operating hours per day. If you run multiple shifts or around-the-clock production, choose a machine that is designed to run continuously without compromising performance or reliability.
Scalability: Consider a machine that can be easily upgraded or modified to accommodate future production growth. This way, you can scale your operations without investing in brand new equipment.
Tube Specifications
Evaluate the characteristics of the tubing that will be used in your production process. Consider the following:
Size: Determine the range of tubing sizes that will need to be filled and sealed. Measure the length, diameter, and nozzle size of your tubing and make sure the machine can accommodate these dimensions. Some machines may have limits on the minimum or maximum tubing size that can be processed.
Shape: Consider the shape of your tubing, such as round, oval, or a unique custom shape. Make sure the machine's filling and sealing mechanisms are compatible with your tubing shape to prevent leaks or sealing issues.
Material: Evaluate the material of your tubing, such as plastic (e.g., polyethylene, polypropylene), laminate, or metal. Different tubing may require specific sealing techniques or treatments. Make sure the machine can handle your tubing efficiently and effectively.
| Tube | Properties | Suitable Sealing Technology |
| Plastic | Flexible, lightweight, cost-effective | Heat seal, ultrasonic seal |
| Laminate | Barrier properties, extended shelf life | Heat seal, hot air seal |
| Metal | Durability, premium appearance | Crimp seal, fold seal |
Product Properties：
Consider the properties of the product you are filling into the tube. Different product types may require specific filling systems and machine configurations. Evaluate the following:
Viscosity: Determine the viscosity range of your product, from low-viscosity liquids to high-viscosity pastes or gels. Select a filling system that can effectively handle the viscosity of your product, ensuring accurate and consistent dosing.
Particle size: If your product contains particles, such as exfoliants or suspensions, consider the maximum particle size and distribution. Select a filling system with the appropriate nozzle size and design to prevent clogging and ensure smooth product flow.
Temperature sensitivity: Evaluate whether your product requires specific temperature control during the filling process, such as hot or cold filling. Choose a machine with an integrated temperature control system to maintain product stability and quality.
Foaming: If your product tends to foam, such as some shampoos or cleansers, consider a machine with a specialized filling system or defoaming mechanism to minimize air entrapment and ensure accurate filling.
| Product Type | Viscosity Range | Suitable Filling System |
| Liquids | Low to Medium | Piston, Peristaltic, Gear Pumps |
| Creams | Medium to High | Piston, Gear Pumps, Progressive Cavity |
| Gels | High | Piston, Progressive Cavity |
| Pastes | Very High | Piston, Screw Pumps |
Performance and quality
When evaluating the performance and quality aspects of a tube filling and sealing machine, consider the following key factors:
Filling accuracy：
Precise and consistent filling is crucial to ensure that each tube contains the specified amount of product. This not only maintains product consistency but also minimizes waste and reduces production costs. When selecting a machine, consider the following aspects:
Dosing technology: Choose a machine with a reliable and accurate dosing system, such as piston, peristaltic, or gear pump fillers. Each technology has its advantages depending on the product type and viscosity.
Filling range: Evaluate the machine's filling range, ensuring that it can accommodate the desired filling volumes for your tubes. Look for machines with adjustable filling parameters to allow for flexible and precise dosing.
Filling nozzles: Consider the design and material of the filling nozzles. Opt for nozzles that are compatible with your product type and can prevent dripping or contamination. Some machines offer quick-change nozzle systems for easy cleaning and maintenance.
Sealing integrity:
A reliable and effective sealing system is essential to ensure the quality and shelf life of your products. Poor sealing can lead to leakage, contamination, and premature product deterioration. When evaluating sealing performance, consider the following factors:
Sealing technology: Select a machine with a proven sealing technology, such as heat sealing or ultrasonic sealing. Heat sealing uses heat and pressure to melt and fuse the tube's edges, creating a strong seal. Ultrasonic sealing uses high-frequency vibrations to create a hermetic seal without the need for additional consumables.
Sealing parameters: Look for machines with adjustable sealing parameters, such as temperature, pressure, and dwell time. This allows you to optimize the sealing process for different tube materials and thicknesses, ensuring consistent and reliable seals.
Seal quality inspection: Consider machines with integrated seal quality inspection systems, such as vision systems or pressure decay testing. These systems can detect seal defects, such as leaks or incomplete seals, and automatically reject defective tubes, ensuring that only quality products reach your customers.
Process control and monitoring:
Advanced tube filling and sealing machines often feature integrated process control and monitoring systems. These systems help maintain consistent quality, optimize production efficiency, and provide valuable data for continuous improvement. When selecting a machine, look for the following features:
PLC control: Machines equipped with programmable logic controllers (PLCs) offer precise control over filling and sealing parameters. PLCs allow for easy recipe management, parameter adjustment, and process automation, reducing manual intervention and ensuring consistent results.
Sensors and monitoring: Consider machines with integrated sensors and monitoring systems that track critical process parameters, such as filling weights, sealing temperatures, and machine speed. These systems provide real-time data and can alert operators to any deviations or issues, enabling quick corrective actions.
Data collection and reporting: Look for machines with data collection and reporting capabilities. This allows you to gather valuable production data, such as output rates, downtime, and quality metrics. By analyzing this data, you can identify improvement opportunities, optimize processes, and make data-driven decisions.
How to Maintain the Tube Filling and Sealing Machine
Regular Maintenance Tasks
Cleaning and Lubrication: Regular cleaning of machine components and lubrication of moving parts helps prevent contamination and ensures smooth operation. Manufacturers should follow the cleaning and lubrication schedule recommended by the machine supplier.
Replacement of Wearable Parts: Over time, some machine parts, such as sealing jaws or filling nozzles, may wear out. Regular inspection and timely replacement of wearable parts can prevent quality problems and extend the life of the machine.
Calibration and Adjustment: Regularly calibrating the filling system and adjusting the sealing parameters are essential to maintain consistent filling accuracy and sealing quality. Manufacturers should perform these tasks according to the machine supplier's guidelines.
Contact Wejing for Efficient Tube Filling and Sealing Machines
Tube filling and sealing machines have revolutionized the packaging process in a variety of industries, from personal care and cosmetics to pharmaceuticals and food. As manufacturers strive to meet growing market demands and maintain a competitive advantage, investing in tube filling and sealing machines may be a strategic decision that can bring long-term value and growth opportunities.
WeJing provides efficient tube filling and sealing machines suitable for daily chemical pharmaceutical, food, chemical industry, etc. If you have any needs, please contact us for consultation.
FAQs
Q: What are the benefits of using a tube filling and sealing machine
Tube filling and sealing machines automate the packaging process, ensuring precise filling, secure sealing, and high production efficiency. They help maintain product consistency, minimize waste, and reduce labor costs.
Q: How do I choose the right tube filling and sealing machine for my business?
Consider factors such as production requirements, tube specifications, product characteristics, and performance features when selecting a tube filling and sealing machine. Evaluate your current and future needs to choose a machine that can scale with your business.
Q: What types of products can be packaged using a tube filling and sealing machine?
Tube filling and sealing machines are suitable for packaging a wide range of semi-solid or viscous products, such as toothpaste, creams, gels, ointments, and food items. They are commonly used in the pharmaceutical, cosmetic, and food industries.
Q: How can I ensure consistent product quality when using a tube filling and sealing machine?
Look for machines with advanced process control and monitoring systems, such as PLC control, sensors, and data collection capabilities. These features help maintain consistent filling accuracy, sealing integrity, and overall product quality.
Q: What maintenance tasks are required for tube filling and sealing machines?
Regular maintenance tasks for tube filling and sealing machines include cleaning, lubrication, replacement of wearable parts, calibration, and adjustment. Follow the machine supplier's guidelines to keep your equipment running smoothly and prevent quality issues.
