Volumetric Filling Machines Vs. Liquid Filling Machines

Modern industries have to perform the daunting task of filling liquid and powder into various packaging containers. They use different filling technologies to accomplish this task.

Two of these common machines are the volumetric filling machine and liquid filling machines.

So where and when should we use a specific filling technology – Let’s analyze the two machines:

What Are Volumetric Filling Machines

We use volumetric technologyto fill products in containers to a specific volume. The product is filled by considering its volume and not the weight or its level in the container.

Vacuum Filling System
Vacuum Filling System

This ensures that each fill has a consistent volume of the product regardless of any variations in the volume of the containers.

We use these volumetric fillers to package products requiring a particular measurement such as medicines and food products.

What Are Liquid Filling Machines

We sometimes refer to them as flow-filling machines. They specifically dispense liquid products into their packaging containers by factoring in their flow properties.

Flow Filling Machine
Flow Filling Machine

When metering these products through them, factors such as viscosity and temperature affect the rate at which the liquid product flows. They fill the product to a specific level that has to be uniform in all containers with their volume variations notwithstanding.

How Volumetric Filling Machines Compare To Liquid Filling Machines

Distinguishing between volumetric and liquid filling machines is crucial if you must choose the most appropriate filling method for your application.

We can simplify this by outlining the various aspects that are common with the two and how they compare as follows:

· Working Principle

Volumetric Filing Machine
Volumetric Filing Machine

Volumetric Fillers: these fillers heavily rely on components such as pistons and pumps when dispensing volumes of products into containers. Here is a step-by-step breakdown of their operating principle:

  • Product Intake: the product is usually stored in large volumes in a storage tank or reservoir. It is from here that it is taken to the piston
  • Measuring Product Volume: once the product enters the piston chamber, it fills up to the preset product volume that is supposed to be filled into the containers
  • Product Filling: based on the motion of the piston with assistance from pumps, the machine dispenses the product into the container. The valves close once the pre-set time is reached and the required volume is filled for automatic fillers.
  • Cycle Ends: once a container is filled with the right product volume, the cycle repeats with the next container getting the same volume of product fill as the previous.

Liquid Fillers: the determinant factor in the operation of these level-fillers is how well they manage liquid flow into the containers. They normally accomplish this using gravity, pressure, or even a vacuum.

Liquid Filling Machine
Liquid Filling Machine

Let us go through the general outline of how level fillers work:

  • Supplying the Fill Product: level fillers normally have reservoir tanks where the processed liquid to be filled is usually stored and supplied to the containers.
  • Regulating The Flow: as the liquid is fed into the containers, their flow is regulated using mechanisms such as valves, pumps, or simply by using gravity.
  • Filling: the flow of the liquid product into the container continues until the required level is achieved.
  • Fill Finishing: once the desired level is achieved, the flow is halted and the nozzle moves to the next container for subsequent fill cycles.

· Types

Volumetric Fillers: modern technology has availed various types of volumetric fillers that we can apply based on our process demands. Some of the most notable ones include:

  • Piston Fillers: It incorporates a piston that draws and dispenses the liquid product into containers. Highly recommended for products that have high viscosity such as creams and pastes.
  • Peristaltic Fillers: these fillers convey the product to the containers using flexible tubing and roller. We widely use them in health-sensitive environments that have sterile requirements such as pharmaceuticals.
  • Gear Pump Fillers: the product is delivered to containers through pumps that are powered by a set of gears. Works well when you are dealing with products having a moderately high viscosity such as oils.

Liquid Fillers: there are several level fillers each suited for different products and applications. Some of them include:

  • Gravity Fillers: they rely on the force of gravity to assist in filling the liquid product into containers. Ideal for filling products regarded as thin liquids such as juice and water that flow freely.
  • Pressure Fillers: use pressure to pack liquid material into containers. Ideal for products that froth or have thick fluids.
  • Vacuum Fillers: This entails the use of pressure in a vacuum to pull the liquid product into the container. Suitable for use with delicate containers and less viscous fluids.
  • Pump Fillers: the liquid product is conveyed into the container using pumps. You can apply it with products having a wide range of viscosity.

· Benefits

Volumetric Fillers:

  • They are highly accurate since they control the amount of space utilized by the product accurately
  • Ensures standardized efficiency since equal amounts of liquid are delivered for every batch
  • Versatility enables them to handle a broad spectrum of viscous products
  • The setup process is not very complicated since they have a clear setting of volume levels

Liquid Fillers:

  • They are flexible enough to handle liquids with various types of viscosity
  • More economical to use compared to volumetric fillers
  • They have good scalability
  • They are easier to maintain

· Drawbacks

Volumetric Fillers:

  • May be costlier than liquid fillers for their initial setup
  • They have a more complex design that also increases maintenance cost
  • Produces large variances with products where weight is more important than volume

· Accuracy And Precision

Volumetric Fillers: they dispense exact volumes of the product with little or no deviation. This is essential for products that rely on consistency such as pharmaceuticals.

Liquid Fillers: though precise, a number of these machines can give you small deviations in fill levels due to temperature changes or viscosity.

· Speed and efficiency

Volumetric Fillers: they normally work at very high speeds. The problem arises when trying to quantify the volumes accurately for highly viscous commodities.

Liquid Fillers: they are usually faster and more efficient with free-flowing liquids having low viscosity. They can endure high throughput rates making them ideal for high-capacity production lines.

· Product versatility

Volumetric Fillers: they offer outstanding flexibility regarding the thickness of the products processed as well as the viscosity of the end product.

Liquid Fillers: it is also more general-purpose but better for steadier flows. Highly viscous products may require complex liquid fillers.

· Maintenance and cost

Volumetric Fillers: they cost more in terms of installation and maintenance due to their complex design.

Liquid Fillers: they are more affordable due to their low initial and operating costs

· Applications

Volumetric Fillers: comes in handy with industries requiring extremely accurate dosing and measurements. Such industries include food, cosmetic and pharmaceutical industries among others.

Liquid Fillers: highly effective for soft drinks, detergents, and liquid food products that require a visual appeal to market them.

Conclusion

Choosing between the volumetric or liquid filling machines will largely depend on your product type, level of precision, quantity of production, and cost. Future trends are bound to increase the versatility and productivity of these two machines.

For all your filling machines, contact us now.

 

More Resources:

Volumetric Filling Machine  – Source: JOCHAMP

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