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Gels filling Equipment

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

The easiest and most commonly used method of making gels is mixing gelling agents with water to form a weakly cohesive internal structure. The gel production process is pretty linear and straightforward, from mixing hydrocolloids and water to labeling and sealing containers.

Gels

<span style="font-weight: 400;">Filling and capping bottles and pots for food, chemical and cosmetics industries using separate machines is expensive and inefficient.A better solution is a combined monoblock unit, that will save space and cost, whilst increasing product throughput, even on multi-product lines.</span>
<h3><b>Monoblock combined filling and sealing machine</b></h3>
<span style="font-weight: 400;">EFM Monoblock filling machine is an easy-to-use, multi-purpose machine designed for filling and capping of containers with lids or pressure caps. Featuring a touchscreen system, the machine is easy to operate and allows simple readout and storage of all function information.</span>

<span style="font-weight: 400;">EFM’s design philosophy is to provide adaptable machines suitable for a range of industries. The Monoblock filling machine can be used with a wide variety of filling methods, including digital flow metering, piston pumps, peristaltic pumps, and more.</span>

<span style="font-weight: 400;">For the sealing process, a choice of methods is available including manual positioning of lids, or use of a fully automated cap supply system that uses pick and place. Final tightening can be by magnetic capping, servo capping, pressure capping or pilfer proof capping, to suit your requirements.</span>

Compact monoblock filler

<span style="font-weight: 400;">In many food, chemicals and cosmetic industry processes it is vital to have a quick, accurate and reliable filling and sealing solution that can handle a wide variety of liquid types, including high viscosity and foaming products, into a range of bottle types.</span>


<h2><b>High capacity filler and capper capable of handling wide range of product</b></h2>
<span style="font-weight: 400;">The EFM Inline Monoblock Linear Filling and Capping series is available in both flowmeter and servo piston configurations to suit your exact requirements. Able to operate at up to 2,600 bottles per hour and fill volumes up to 30,000ml depending on model configuration, the Inline Monoblock is constructed in the Netherlands using all stainless steel and standardised components for longevity and ease of maintenance. Remote support from EFM engineers is also available for full peace of mind.</span>

<span style="font-weight: 400;">All variants features Siemens PLC and touchscreen controls, and all product contact points are of 316 stainless steel construction for longer life even when used with corrosive product. A polycarbonate safety casing gives superior protection and allows for excellent visibility for monitoring the filling and capping cycle. The capping module features high-torque sealing and a self-contained Detect and Reject operation to confirm the integrity of the seal, ensuring product quality.</span>

<span style="font-weight: 400;">The flowmeter variants are fitted with Endress &amp; Hauser Mag or Mass flowmeters, and both flowmeter and servo piston versions feature bottle counting, individual centering detection and automated filling bridge height adjustment.</span>

In-line monoblock linear filler &amp; capper

<span style="font-weight: 400;">For the stand-alone capping of bottles of up to 2.5litre capacity you need a robust and flexible machine with high speed and accuracy. Used in the beverage and chemicals industries, bottle cappers need to be reliable and fast, and for maximum flexibility need to be able to deal with a range of caps.</span>


<h2><b>Fully automated standalone capper for bottles up to 2.5 litre</b></h2>
<span style="font-weight: 400;">The EFM range of Multi-Head Capping machines offer maximum flexibility together with impressive performance. These all-stainless machines feature Siemens PLC and full touchscreen controls for accuracy and ease of use. The use of standardised components throughout from high-quality manufacturers increases longevity and reduces the downtime for any maintenance. The gravity-fed cap sorter and magnetic torque head provide high levels of reliability.</span>

<span style="font-weight: 400;">Able to handle a wide range of caps types, including screw caps, push ons, non-vacuum twist-offs and pilfer proof, the EFM multi-head range includes variants able to operate from 4,000 bottles per hour up to 9,000 bottles per hour with the 8 head unit.</span>

<span style="font-weight: 400;">Flexible options include screw infeed, second cap sorter for extremely quick changeovers, torque verification and Detect and Reject system for full capping verification. The units are also available with an optional remote support package direct from the manufacturer.</span>

Multi-head capper

<span style="font-weight: 400;">For food and non-food liquid products that are high foam or have a high viscosity a specialist filling solution is required. Whether filling jars, cans, bottles, top-downs or bowls, the filling machine needs to offer high levels of accuracy and reliability whilst being able to operate at high volumes.</span>


<h2><b>Servo-controlled piston filling machine for high viscosity liquids</b></h2>
<span style="font-weight: 400;">The EFM Servo Piston range of filling machines has been designed specifically for use with high viscosity and high foam liquids in the food, chemical and cosmetics sectors. Featuring robust all-stainless construction and high quality Siemens PLC and touchscreen control, the Servo Piston variants offer accurate and reliable fills at up to 5,200 bottle per hour.</span>

<span style="font-weight: 400;">Featuring standardised components for ease of maintenance and minimal downtime, the EFM servo piston machines are designed to handle volume ranges from 15cc up to 1,100cc depending on configuration.</span>

<span style="font-weight: 400;">For speciality products there are a wide range of options and upgrades available, including heated product tank, product agitators and nitrogen injection.</span>

<span style="font-weight: 400;">Constructed in the Netherlands, EFM also offers an optional remote support service for complete peace of mind.</span>

Servo controlled filler

<span style="font-weight: 400;">For the stand-alone capping of bottles of up to 30 litre capacity for smaller-scale production you need a robust and flexible machine with high accuracy. Used in the beverage and chemicals industries, bottle cappers need to be reliable and fast, and for maximum flexibility need to be able to deal with a range of caps.</span>


<h2><b>Flexible single-head capping machine for smaller-scale production lines</b></h2>
<span style="font-weight: 400;">The EFM range of single head capping machines offer maximum flexibility together with impressive performance for smaller scale production lines. These all-stainless machines feature Siemens PLC and full touchscreen controls for accuracy and ease of use. The use of standardised components throughout from high-quality manufacturers increases longevity and reduces the downtime for any maintenance. The gravity-fed cap sorter and magnetic torque head provide high levels of reliability.</span>

<span style="font-weight: 400;">Able to handle a wide range of caps types, including screw caps, push ons, non-vacuum twist-offs and pilfer proof, the EFM single-head range includes a standard edition able to cap up to 2,200 bottles per hour, and a servo-controlled edition capable of up to 2,600 bottles per hour.</span>

<span style="font-weight: 400;">Featuring a star wheel positioner as standard, the machine is able to fill bottle of up to 2.5 litres. However, by specifying the option using gates larger packages from 5 up to 30 litres can be filled by this machine, providing great flexibility.</span>

<span style="font-weight: 400;">Other options include high torque sealing, torque verification and Detect and Reject system for full capping verification. The units are also available with an optional remote support package direct from the manufacturer.</span>

Single head capper

<span style="font-weight: 400;">A wide variety of pharmaceutical, cosmetic and food products require tube-style packaging. An automated tube-filler adds flexibility to production lines by not only filling, sealing and capping tubes with high levels of accuracy, but also offering additional features such as labelling and in-built quality checks.</span>


<h2>Tube filler with additional flexible features</h2>
<span style="font-weight: 400;">The TFS-15 from IWK is an automatic tube filling machine that operates in the lower speed range, and is suitable for moderate scale production lines. It features 10 workstations that can handle tubes from 10 to 60mm diameter and can accurately dose from between 1.5 ml and 400 ml of product at up to 90 tubes per minute. High-precision dosing is guaranteed by an infinitely variable, play-free direct pump drive.</span>

<span style="font-weight: 400;">The highly flexible TFS-15 allows for rapid changeover between tube and product types. Product-handling parts are changed out as one unit. Sizing parts can be simply and quickly changed out without the use of tools. These minimise downtime associated with product changes.</span>

<span style="font-weight: 400;">The TFS-15 also offers two-component filling and the ability to fill applicators, expanding the range of products it can be used with. Labelling can be achieved with laser or inkjet printing as well as embossing.</span>

<span style="font-weight: 400;">Designed to deliver constant high quality tube folding or sealing, the TFS-15 has inbuilt quality control checking that will detect and eject bad tube seals and incorrectly fitted or missing caps.</span>

<span style="font-weight: 400;">Suitable for use with a wide range of products, the TFS-15 can fill and close cylindrical (with EURO-hole, curved seal) oval or conical tubes, dispensers (including inserting of pistons), mascara brushes, cartouches, jars, and tottles (with capping).</span>

A two-component filling application tube filler

<span style="font-weight: 400;">Increasing numbers of products in the pharmaceutical, cosmetic and food industries are delivered in flexible tubes, bottles or dispensers. Automated tube filling machines improve production efficiency by accurately filling, sealing and capping a range of tube-based packaging with minimal operator intervention. For smaller-scale production environments, large filling machinery is impractical and expensive.</span>


<h2>Automatic tube filler for small scale production</h2>
<span style="font-weight: 400;">The FP-10 from IWK is a next-generation tube filling machine that operates at lower speeds, most suited for small scale production. It features 10 workstations that can handle tubes from 10 to 52mm diameter and can accurately dose from between 1.5 ml and 300 ml of product at up to 70 tubes per minute.</span>

<span style="font-weight: 400;">The FP-10 has been designed to allow for rapid product changeover, and all components can be switched out in a little as 15 minutes, keeping downtime to a minimum.</span>

<span style="font-weight: 400;">The FP-10 benefits from the latest servo technology, giving the machine extremely high reliability and minimum maintenance. A new 5.7” touch panel HMI not only displays all relevant process parameters, but also allows profile storage and data recording. Internet connectivity allows for remote diagnostics and servicing.</span>

<span style="font-weight: 400;">Able to fill metal or plastic containers, the FP-10 can perfectly contour seal plastics with hot air and offers double, triple or saddle folding for metal tubes to meet your exact requirements.</span>

<span style="font-weight: 400;">Suitable for use with a wide range of products, the FP-10 can fill and close cylindrical (with EURO-hole, curved seal) oval or conical tubes, dispensers (including inserting of pistons), mascara brushes, cartouches, jars, and tottles (with capping).</span>

Low speed tube filler

<span style="font-weight: 400;">For scale-up filling of tube packaging for pharmaceuticals, cosmetics and food products, a medium-speed automatic tube filler is required that meets increased demands of speed and volume with high levels of accuracy and minimum downtime. The ability to handle a wide variety of packaging types, and to cap and seal in different ways means additional flexibility that results in increased efficiency.</span>


<h2>Scale-up tube filler for increased efficiency at higher volumes</h2>
<span style="font-weight: 400;">The IWK FP Series is a latest-generation modular filling and sealing machine for tube-based containers. Designed with reliability, ease of use and performance as a priority, the FP Series uses the latest servo technology throughout to provide industry-leading levels of reliability.</span>

<span style="font-weight: 400;">The range features 18 to 64 workstations that can handle tubes from 10 to 63mm diameter and can accurately dose from between 1.5 ml and 700 ml of product at up to 300 tubes per minute.</span>

<span style="font-weight: 400;">The modular design of the FP Series allows it to be configured to your exact requirements, both in terms of operations and functions and floor layout. 5 servo drives (with an additional 4 as options) are at the heart of the oval transport system and offer high level of accuracy together with a robustness that keeps maintenance and downtime to a minimum.</span>

<span style="font-weight: 400;">The FP Series is available with a large range of options that means it can be tailored to your exact requirements. Options include tube feeding systems, in-line checkweighing, frequency welding, droplet dosing and many more.</span>

<span style="font-weight: 400;">Multi-colour tube filling is available and features the IWK patented swing-out quick change system for rapid changeover. Multi-colour fill types include sandwich, deep stripe, surface stripes and core striping.</span>

<span style="font-weight: 400;">The newly designed HMI features a 15” touchscreen control with graphical status reporting and diagnostics, and is fully 21CFR part 11 compliant for auditing and reporting.</span>

Medium speed tube filler and sealer

<span style="font-weight: 400;">When scaling up production of pharmaceutical, food or cosmetic products that use tube containers, increasing speed and throughput without compromising on accuracy and quality are vital. Tube fillers need to be able to handle a wide range of packaging types and allow for rapid changeover to benefit from their flexibility and speed.</span>


<h2>Small footprint, GMP-design medium to high speed tube filler</h2>
<span style="font-weight: 400;">The IWK TFS-E Series benefits from a range of innovations that result in a robust, easy-to-use and maintenance-free tube filling solution for medium scale production.</span>

<span style="font-weight: 400;">The TFS-E Series features 20 workstations that can handle tubes from 11 to 52mm diameter and can accurately dose from between 1 ml and 350 ml of product at up to 220 tubes per minute.</span>

<span style="font-weight: 400;">Designed with flexibility in mind, the TFS-E features a format change over time of less than 25 minutes, and storing and recalling all relevant process parameters to guarantee a vertical start up. All product-contacting parts are swapped out “en bloc” which gives the maximum efficiency whilst allowing for a range of product. The patented IWK dosing system is supremely accurate but also simple to maintain, thanks to Clean in Place in under 5 minutes.</span>

<span style="font-weight: 400;">Able to fill metal or plastic containers, the TFS-E Series can accurately contour seal plastics, and offer a choice of double, triple or saddle folding for metal tubes to meet your needs.</span>

<span style="font-weight: 400;">Suitable for use with a wide range of products, the TFS-E Series can fill and close cylindrical (with EURO-hole, curved seal) oval or conical tubes, dispensers (including inserting of pistons), mascara brushes, cartouches, jars, and tottles (with capping).</span>

<span style="font-weight: 400;">A wide range of options enables the TFS-E Series to be specified exactly to your requirements. Options include multi-colour filling, tube de-dusting, in-line checkweighing, automatic central lubrication system, and many more.</span>

Medium and high speed range automatic tube filler

<span style="font-weight: 400;">For high-volume lines filling pharmaceutical, cosmetic or food products into tube containers, high speed and throughput must not come at the compromise of fill accuracy and sealing quality. High performance tube filling machines successfully match performance with quality, using a range of technological advances to ensure the maximum efficiency and rapid ROI.</span>


<h2>World’s fastest high efficiency tube filler with advanced features</h2>
<span style="font-weight: 400;">The TFS-80 Series from IWK is a high-performance, next-generation tube filling machine that is most suited for large scale production environments. It features up to 24  workstations that can handle tubes from 22 to 40mm in diameter and can accurately dose from between 2 ml and 220 ml of product at up to 750 tubes per minute.</span>

<span style="font-weight: 400;">The TFS-80 Series is officially the world's fastest tube filler, and yet it’s new weight checking and quality control system guarantees accuracy, reducing tube overfilling significantly. By using a clever modular design, workstations can be retrofitted with ease for maximum flexibility and future expansion, making development of new packaging or product types simple.</span>

<span style="font-weight: 400;">Because it operates with such high performance, the TFS-80 Series has been engineered for reliability and efficiency. Many traditional mechanical actions have been rendered obsolete by the use of servo technology throughout. State of the art bearings with central lubrication system allow for long service intervals, reducing maintenance costs. </span>

<span style="font-weight: 400;">For greatly reduced downtime caused by product changes, fast exchange systems are employed. New motion parameters are automatically set via servo drives in case of product changes. The touch screen panel HMI makes these operations quick and easy, as well as allowing simple monitoring of the machine in use. Internet access allows remote diagnostics, further reducing any downtime.</span>

<span style="font-weight: 400;">Despite the high performance of the TFS-80 Series, it’s been designed to occupy as compact a form-factor as possible, providing maximum flexibility when it comes to your own installation.</span>

High speed automatic tube filler

<span style="font-weight: 400;">High performance tube-filling machines are used in the pharmaceutical and cosmetic industries. Their performance is greatly enhanced by the use of automated feed-in systems, delivery the empty tubes accurately and quickly to maximise the efficiency of the filler. Loading systems are available in a variety of formats, including the flexible cassette type.</span>


<h2>Feed cylindrical tubes via a cassette</h2>
<span style="font-weight: 400;">Ensuring a constant supply of appropriately orientated empty tubes, the IWK TZM Cassette Tube Feeding Magazine is suitable to supply machines operating at up to 120 tubes per minute.</span>

<span style="font-weight: 400;">The TZM allows for uninterrupted operation because it holds tubes in a reservoir between the tube filler and tube feeding magazine. Tubes in the reservoir are processed first, meaning restocking the filler will not impact on the operation. A photo-electric backup sensor monitors</span>

<span style="font-weight: 400;">the tubes in the reservoir ensuring it does not run empty.</span>

<span style="font-weight: 400;">The TZM aligns tubes into singles by using pneumatic baffle plate movements in the magazine and the reservoir area. Individual tubes are picked up at the far end of the tube filler chute and loaded in the tube filling machine.</span>

<span style="font-weight: 400;">Suitable for use with laminar flow, the TZM gently handles tubes, minimising damage to fragile materials. The TZM is able to handle all commercially available tube materials, and operates with tubes of diameter 13.5 mm to 40 mm, and length 60 mm to 230 mm.</span>

<span style="font-weight: 400;">Size changeovers are very quick to minimise downtime and don’t require the use of any tools.</span>

Loading cassette for a tube filler

From thin liquid baby oils and perfumes to thicker lotions and creams for hair and skincare, cosmetic products include a wide range of goods. In an industry where there are a plethora of product types, it’s essential to use a filling machine that can be adapted to the different consistencies of lotions and creams.
<h2>Automatically fills and closes jars, glasses, and tins for cream</h2>
Engineered by Wick Machinery, the DFB-T delivers an output of 400 containers per minute and has a filling range of 1 to 300 ml. The in-feed of jars or empty containers can be done manually, by a disc sorting machine, and by a rotary table. All containers are air-cleaned, while various filling systems enable product-specific filling.

The model also features jar coding, film die and foil cutters for precise filling. It also features a sealing station for hot sealing of foil on glass and plastic containers. Lastly, its filling nozzles are specifically designed for individual products, making the DFB-T ideal for tins, glasses, and jars.

Cosmetic cream filler

Industrial settings requiring efficient and precise bottle filling and capping often face challenges in maintaining consistency and minimizing waste. These processes need to handle varying container sizes and ensure product integrity during packaging.
<h2>Streamline your bottle filling and capping process</h2>
The Axofill Axocap by Axomatic (Marchesini Group) is a complete bottle filling and capping line designed for operational efficiency. The system includes a rotating table that loads stable containers and a filling unit with 2 or 4 filling systems, optimizing throughput. The outlet belt can connect to a capping or labeling machine, facilitating seamless integration into existing production lines. The dosing group features adjustable diving nozzles with a stroke range between 30 and 200mm, accommodating various container sizes. Constructed from AISI 304L stainless steel, the durable machine frame ensures long-lasting performance. The electrical installation is strategically placed below the machine perimeter, coupled with a frontal control panel for easy operator access. With a maximum speed ranging from 20 to 50 pieces per minute depending on the quantity to be dosed, the system is versatile for different production needs. Container diameters range from a minimum of 30mm to a maximum of 110mm, and heights from 50mm to 250mm.

Automatic bottle filling and capping line

In the cosmetic and pharmaceutical industries, ensuring precise and efficient filling and closing of tubes is critical to maintaining product quality and reducing waste. This requirement often poses challenges related to consistency, speed, and adaptability to different tube materials and sizes.
<h2>Accurate filling and reliable sealing of tubes</h2>
The AXO 1000 by Axomatic (Marchesini Group) is an automatic tube filling and closing solution designed for aluminum, politene, and metal tubes. This equipment offers a high output capability of up to 5,100 pieces per hour. The touch-screen control panel simplifies the operation, providing easily accessible main functions. It boasts an automatic tube loading feature from the tube magazine and ensures precise orientation and filling through a mechanical dosing system with a dosage range from 3 to 250 ml. The diving nozzle ensures accurate dosage at the bottom of the tube with an adjustable stroke of 130mm. For aluminum tubes, it uses a mechanical jaw closing system, while politene and laminated tubes are sealed using hot jaws or hot air systems. The ultrasonic sealing option is available for politene tubes, offering various custom sealing patterns like round edge, curved seal, and wave seal. This equipment can handle tube diameters from 13.5mm to 50mm (60mm optional) and tube heights from 70mm to 250mm, with 10 stations in total. It is suited for high-speed operations with a speed of up to 85 pieces per minute.

Automatic tube filling and closing solution

In various manufacturing settings, ensuring precise filling and secure sealing of tubes, such as aluminum or plastic ones, is essential. Challenges like inconsistent dosage and poor sealing can lead to product waste and quality issues.
<h2>Fill and close tubes efficiently and accurately</h2>
The AXO 780 by Axomatic (Marchesini Group) is a semi-automatic system designed specifically for filling and closing aluminum, polyethylene, or metal tubes. It offers a manual tube loading option from the magazine and automatic tube orientation (optional). The mechanical dosing system allows for filling volumes between 3 and 250ml, with an optional range up to 450ml. A diving nozzle ensures accurate bottom filling with a fixed stroke of 70mm. For sealing, the system uses mechanical jaw closing for aluminum tubes and hot air or ultrasonic sealing for polyethylene, laminated, and polyfoil tubes. Custom sealing patterns like round edge, curved seal, and wave seal are also possible. The machine can handle plastic tubes up to 60mm in diameter and processes up to 2,400 pieces per hour.

Semi-automatic tube filling and closing system

In the health and beauty industry, efficient and precise filling and sealing of tubes for products like creams, gels, and lotions is crucial. Frequent changes in product sizes and formulations require a versatile system that ensures seamless transitions and minimizes downtime.
<h2>Automate tube filling with high precision</h2>
The KX903 by Citus-Kalix, part of the Coesia Group, is a high-efficiency tube filling system designed to meet the rigorous demands of the cosmetic and pharmaceutical industries. Capable of filling up to 90 tubes per minute, this system features an automatic tube loading mechanism that allows a single operator to manage frequent size changes with ease. Changeovers are swift—requiring just 5 minutes for a new product and less than 15 minutes for a new tube size—thanks to its recipe settings registration. The filling assembly can be disassembled without the need for tools, simplifying cleaning and reducing downtime. Constructed with a compact, durable unpainted stainless steel finish, the KX903 is ideal for sterile, controlled environments. With a maximum filling volume of 400 ml and the ability to handle tube diameters from 13 mm to 50 mm and lengths from 50 mm to 230 mm, it accommodates a wide range of packaging requirements. The machine complies with safety regulations 2006/42/EC, 2014/30/UE, and 2014/35/UE.

Tube filling solution for health and beauty products

Producing high-quality lotions, creams, and gels requires specialized equipment due to the complexity of mixing and homogenizing high-viscosity products. This ensures uniform texture and optimal product quality, which traditional methods often fail to achieve efficiently.
<h2>Homogenize and mix with precision and speed</h2>
The EKATO UNIMIX vacuum processing units offer a versatile solution for producing various high-viscosity products such as lotions, creams, gels, and toothpastes. Combining the patented EKATO PARAVISC impeller and the EKATO S-JET homogenizer, these units ensure rapid, effective mixing and homogenization. The PARAVISC impeller provides excellent axial mixing, while its open design allows for the use of a central baffle and wall scrapers, optimizing heat transfer. The S-JET homogenizer is designed for internal and external homogenization, enabling swift and precise product dispersion. The system supports capacities ranging from 100 liters to 20,000 liters and includes features like heating and cooling functions, automated feeding, and Cleaning in Place (CIP) systems. It meets ASME, PED, and SELO standards, ensuring reliable performance across industries such as cosmetics and pharmaceuticals.

Vacuum processing units for high-viscosity products

When handling a diverse range of liquid to pasty products, maintaining high flexibility and efficiency is crucial. Traditional filling systems may lack the versatility required for various container types and product viscosities, posing production challenges.
<h2>Fill and seal pre-formed containers efficiently</h2>
The R-Line, from IMA Group, is a versatile rotary filler designed for various applications. It boasts a modular design concept that prioritizes flexibility, enhancing both accessibility and sustainability. Capable of filling products from liquids to high-viscosity pastes, the R-Line accommodates pre-formed cups, tubs, buckets, glass jars, and bottles. It supports the use of recyclable mono-material and paper-based cups and lids. With an output capacity of up to 36,000 cups per hour, depending on the cup size and volume, the machine meets diverse production needs. The R-Line comes in four versions (S, M, L, XL), each with specific dimensions and capabilities, ensuring suitability for different production scales. The open design and wash-down capabilities ensure hygienic operations, ranging from 'Clean' to 'Aseptic Ready'.

Rotary filling and sealing for liquid to pasty products

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