Before investing in your next auger filling machine, it is important to understand the basic working principle.
That is, how each components in auger filler coordinate to dispense accurate amount of powder into containers.
So if you want to learn about the fundamental aspects about auger filler working principle, read this guide.
Working Principle of Auger Fill
The auger filing process is based on the operation of a rotating auger screw, essential in product movement.
In order to understand the auger filling machine working principle, let us explore how each part functions.
Remember, every part plays an important role in the auger powder filling process allowing you to make accurate product dispensations.
How Hopper in Auger Filler Works
The hopper part of an auger filler is critical in the storage and feeding of the product to the auger filling mechanism. It ensures smooth and efficient operation while maintaining hygiene standards by avoiding human and other unwanted interaction.
You hold or store product intended for packaging via auger screw filling in the hopper. It is typically of stainless-steel construction owing to its superior qualities of corrosion resistance, durability and ease of cleaning. Its design and construction are tailored to the specific application and industry needs.
Hoppers come in different sizes capable of varying capacities depending on the product type and production requirements. When handling small auger filling operations like filling capsules, you can utilize a small hopper. Alternatively, large operations like auger screw filling flour require large hoppers.
It is worth noting that hoppers in auger fillers are usually conical or cylindrical, the former more prevalent in large-scale production environments. Having a conical shape for your auger filler design promotes efficient feeding as the product flows towards the bottom.
The principle of auger powder filling is such that the hopper is mounted above the auger filler frame. This could be directly over the auger mechanism or through establishing a connection between the two via a feed tube/chute.
Integration of the hopper to the auger filler structure is seamless sometimes featuring removable clamps to aid in installation and removal. They can also feature rotating paddles or vibratory motors as agitation mechanisms to prevent products with poor flow characteristics from clogging.
In continuous operations requiring just the right amount of product in the hopper, installing level sensors ensures optimal product levels. This avoids hopper overfilling or underfilling as the sensor communicates with the auger filler’s control system.
The working principle of an auger commences with product loading into the hopper manually or through an automated feeding system. By virtue of the hopper design, product movement towards the auger mechanism is gravity assisted.
Cleaning hoppers is made simple thanks to their smooth and rounded surfaces that prevents residue accumulation that can result in contamination. Additionally, having access panels that can be removed allows you to reach the interior surfaces during inspection and cleaning.
How Auger Tooling System Works
An auger filler’s tooling part includes components that directly handle and manipulate the product being dispensed. These tooling components collectively work to ensure filling operations are accurate and efficient. These components consist: the agitating blade, auger and funnel.
Agitating Blade Working Principle
This component is usually close to the hopper base where it agitates the product ensuring flow consistency towards the auger. This way, the agitating blade helps prevent clumping, bridging, or product settling within the hopper.
You have agitating blades that are stationary while some are movable depending on the auger filler design. Movable blades may be connected to the auger screw filler’s main drive system or powered by a separate motor. Agitating blades are commonly fashioned from stainless steel for its unique properties.
Working of Auger
The working principle of the auger is central to the operation of an auger filler. It is a rotating helical screw that picks up the product and moves it towards the filling area. As the primary component, the auger meters and transports the product to the filling nozzle from the hopper.
When describing an auger screw design, the parameters of diameter, pitch, and flight are pivotal. This is because they are dependent on factors like product characteristics such as particle size and flowability, as well as filling accuracy.
Stainless steel’s unique properties of corrosion resistance and durability make it ideal for making auger screws. The auger filler working principle is such that the auger screw rotates continuously when the filler is in operation.
In product metering, rotation of the auger picks up product from the hopper bottom before being carried upwards. Product volume in a single rotation is determined by the pitch of the auger flights. Additionally, the product amount that is dispensed is determined by rotation speed and duration.
Sometimes, a compaction mechanism is included to ensure accurate product measurement and prevention of voids in the product. Such a mechanism may utilize a tamping device or compression cone that compresses the product as it courses along the auger.
How Funnel in Auger Filler Works
Located at the auger filler’s base, the funnel directs the product into the packaging container from the auger mechanism. The funnel’s design is such that it corresponds to the opening of the container being filled. As such, it can be customized to accommodate different container sizes and shapes.
Making the funnel to be container specific ensures product flow is precise and controlled. Funnels are typically stainless steel or plastic and can include custom features like interchangeability and adjustable height. These allows you to accommodate the needs of different packaging units.
The funnel conducts product dispensing once the desired product amount has been metered and compacted. Additionally, auger fillers can be equipped with mechanisms to control the filling process ensuring accurate dosing. Sensors can detect when the container is full and stop the filling process.
Working of Drive Assembly for Accurate Auger Filling
An auger filler’s drive system is responsible for powering the rotation of the auger screw. This ensures the auger functions as expected with regard to product metering and dispensing. The drive system consists of multiple components including the motor, gearbox, and drive shaft.
Working of Motor
The drive system is powered by the motor which provides the necessary torque to rotate the auger screw at the desired speed. Auger fillers mostly use variants of electric motors depending on the filler machine design and requirements. The motor type is influenced by the auger size, product consistency and density, and filling speed.
How Gearbox Works
The motor is typically connected to a gearbox which serves to reduce motor speed while increasing torque output. This way, the auger screw can rotate at the desired speed for accurate product metering and dispensing. The gearbox functioning this way an also be used to control rotation ensuring smooth filler operation.
Working of Drive Shaft
The auger screw is connected to the gear box via the drive shaft which transmits rotational motion. This allows movement of the product from the hopper to the filling nozzle. The drive shaft is made from highly formidable and durable components to withstand the torque and stresses involved.
Control System for Functioning of Auger Filler
The control system allows you to adjust settings, set parameters and monitor performance for an optimized process. The control system encompasses the following elements:
User Interface for Auger Filling Process
The user interface of a control system allows you to easily and simply interact with the auger filler. The user interface encompasses knobs, buttons, switches and a display screen allowing you to input commands. Through the display screen, you can view production stats, error messages and other filling parameters.
Parameter Settings for Auger Filler Working Principle
Some of the parameters you can set and adjust on the control panel include filling volume and speed. The filling volume constitutes the product amount dispensed into a container. Filling speed denotes the rotation speed of the auger screw which determines dispensing rate.
Through the control systems, some auger filling machine designs allow you to change the direction of rotation of an auger. These auger screw fillers have reversible modes to accommodate product types of different characteristics. Similalrly, you can adjust agitation settings like speed and interval for the agitating blade to mitigate product settling or bridging.
Production Monitoring
The control system also allows you to monitor in real-time production parameters not limited to filling speed, volume accuracy, and production counts. You can use this information to track auger filler performance, identify deviations, and make suitable adjustments as needed.
The control system can sound an alarm or display a warning message in the event of a deviation from set parameters, malfunction or error. This way, you can quickly identify and address the issue, minimizing downtime.
Safety
Another important element of the control system is the integrated safety features. Auger screw filling machines have been designed with sensors and emergency stop buttons, to ensure operator safety and accident prevention. Safety features allow you to respond quickly to an emergency situation.
Conclusion
Using an auger filler in your production process can immensely improve product quality and increase productivity, achieving greater operational efficiency. It is thus a valuable investment for your business when seeking to enhance your packaging capabilities.
More Resources:
Auger Filler Packing Machine – Source: JOCHAMP
Auger Filler – Source: JOCHAMP