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Liquid detergents 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

Although invented in the early 20th century by Otto Rohm, detergents gained popularity in the 1950s due to the development of modern technology and washing machines which started replacing scrub boards. The liquid detergent manufacturing process involves three key stages: soap premix manufacture, ingredient mixing and enzyme addition.

Liquid detergents

In terms of high-frequency technology, the fill level detection is considered a standard method nowadays. It inspects glasses and PET bottles of almost any shape and colour, in particular for liquids with little or no foam.


<h2>Inspect the filling level for liquids with little or no foam</h2>
The Newton HF from Miho greatly improves the HF measurement process. Without carrying out any special precautionary measures, the HF technology is very sensitive towards changes in temperature that lead to measuring drifts and eventually to changes in the fill levels measured. Miho Newton HF resolves these problems because it is a machine that permanently controls and calibrates itself.

Miho Newton High-frequency fill level controller represents a level of accuracy and reliability that has not been known up until now thanks to the HF fill level control. With this machine the HF inspection process has certainly reached new heights.

High-frequency fill level controller

Accurate fill level inspection for transparent, opaque and foaming liquids, that makes sure the cap is an exact fit.


<h2>Optical precision fill level inspection</h2>
The Newton Optical fill level controller, from Miho performs a precise fill level inspection that is hard to match. This precise level measurement is technically based on a special camera light construction. The images are evaluated by the image-processing system Miho videos that have been designed specifically by Miho Inspection system for inspection tasks.

Cap inspection: The Miho Newton Optic 2 checks that the cap fits exactly. Furthermore, the color and logo can be checked by using an additional camera. This Optical fill level controller is with all its technical ingenuity a very robust and low-maintenance system. Unlike machines that use radiation or X-ray technology, no statutory requirements need to be observed.

Optical fill level controller

For containers that are difficult to see through, such as cans or cartons lined with aluminium, an X-ray inspection can be a good solution when looking for fill level control.


<h2>Fill level inspection for cans, cartons lined with aluminium and foiled containers and bottles</h2>
The Newton X2p from Miho is an X-ray fill level inspection unit that inspects cans, cartons lined with aluminium and foiled containers and bottles. The X-ray fill level controller distinguishes itself by requiring less than a tenth of the average amount usually used during the radioactive inspection for its measurement process.

Its core piece is an X-ray generator, which in contrast to traditional X-ray fill level inspection units only generates X-rays for a short moment during the measurement. The total radiation intensity is, therefore, only a fraction of what is the case with traditional X-ray fill level inspection units. The exact value depends upon the number of containers inspected.

X-ray fill level controller

Large volume plastic bottling plants need high-speed unscramblers suitable for larger plastic bottles. Large format unscramblers designed for speed can compromise on accuracy, increasing rough handling and damage, so a dedicated high speed unit that can gently handle large vessels will increase line efficiency whilst maintaining quality.


<h2>High-speed unscrambler specifically designed for careful handling of larger containers</h2>
The Lanfranchi Classic range of unscramblers have been specifically designed for the highest speeds and most gentle handling for medium to large size containers for beverages and soft drinks.

Built in stainless steel and designed for minimal maintenance and continuous 3-shift use, the Compact unscrambler range can gently handle up to 75,000 bottles per hour using patented No Scuff Technology. Automatic rejection of any damaged bottles (usually without stopping the machine) increases uptime.

Vacuum powered output starwheel offers enhanced flexibility. No outer guide rail means changeover to different size bottles requires minimal intervention as bottles of different sizes can be accommodated easily.

Options are available designed to maximise output speed for lines which use particularly lightweight bottles (to minimise bouncing), or lower speeds using larger, more stable bottles. There is a COMPACT model and option available to suit all production requirements.

High-speed unscrambler for large bottles

Large-scale production of smaller volume bottled product needs a gentle, accurate yet high-speed unscrambler suited to the task. Traditional small format unscramblers can compromise on speed, so a dedicated high speed unit that can gently handle smaller vessels will increase line efficiency whilst maintaining quality.


<h2>High-speed unscrambler specifically designed for careful handling of smaller containers</h2>
The Lanfranchi Compact range of unscramblers has been specifically designed for the highest speeds and most gentle handling for containers up to 270mm tall.

Built in stainless steel and designed for minimal maintenance and continuous 3-shift use, the Compact unscrambler range can gently handle up to 64,000 bottles per hour using patented No Scuff Technology.

Vacuum powered output starwheel offers enhanced flexibility. No outer guide rail means changeover to different size bottles requires minimal intervention as bottles of different sizes can be accommodated easily.

Options are available from Lanfranchi designed to maximise output speed for lines which use particularly lightweight bottles (to minimise bouncing), or lower speeds using larger, more stable bottles. There is a COMPACT model and options available to suit all production requirements.

High-speed unscrambler for small bottles

Smaller plastic bottling lines need a lower cost, lower volume unscrambling machine that maintains gentle handling characteristics and high quality. A new generation of low speed unscramblers meets the needs of smaller scale production perfectly.


<h2>Low-speed unscrambler with precision product handling</h2>
Lanfranchi have brought the same exacting build quality and delicate product handling of their high-speed, high volume machines to the new more affordable ECO range of unscramblers.

Available in 800mm diameter (ECO-S) and 1400mm diameter (ECO-M), the Lanfranchi ECO does not compromise in its construction, featuring stainless steel throughout and full frequency inverter control for precise operation.

As well as a small form factor the ECO has been designed to be adaptable and is easy to work on for product change or cleaning. It's fully automatic, including faulty bottle removal, and includes table-top conveyors and out-feed star wheel all with vacuum.

Low-speed unscrambler

Traditional filling solutions are not appropriate for corrosive substances as they make extensive use of metal parts. For dosing and capping acidic products a specially-designed filling solution is required. As well as resisting the corrosive properties of the product, an acid filling machine needs to deliver good levels of throughput while being reliable and energy efficient.
<h2>Rotary monoblock machine for dosing and capping corrosive products</h2>
The IC series from CMI Industries is a purpose-designed dosing and capping solution for corrosive and acidic products. Offering a pressure gravity dosing system, the IC series features pneumatic valves with viton seals and a no-drop system.

With an in-feed and out-feed conveyor, the IC is able to handle a wide range of bottle and cap sizes. Where specified, format changeover is straightforward, keeping downtime to a minimum.

The capping unit has screwing heads that can be controlled by mechanical clutch or by pressing heads, depending on cap configuration, and have full speed control.

Other options include perfume injection after filling - Dosajet system.

Acid filling machine

Filling of liquid detergents requires specialised equipment because of the foaming nature of the product. Some detergents can also be corrosive, making traditional filling solutions impractical. A modern, purpose-designed filling system for corrosive detergents provides the most efficient and cost-effective solution for these products.
<h2>Rotary filling machine for corrosive and non-corrosive detergents</h2>
The IP Series from CMI Industries is a purpose-built solution for filling foaming detergent products, both corrosive and non-corrosive products. The liquid delivery valves are made of stainless steel, or titanium for corrosive products. The self-priming dosing pump is also made from stainless steel, or plastic where this is required.

The IP series features a rotary caps sorter with automatic pick and place system to ensure accurate delivery to the screwing heads. The heads are fully speed adjustable and controlled by a magnetic clutch, or the use of pressing heads.

A wide range of options is available to tailor the IP Series to your exact requirements, including a centralized adjustment system for the liquid level in the dosing cylinders, dosing units made of stainless steel or Pyrex glass, automatic control device to ensure the cap has been screwed onto the bottle, with rejection of uncapped bottles.

Liquid detergent filling machine

Large-volume parenteral bottles are usually manufactured with a resin that can be autoclaved. These bottles are used to store solutions for irrigation, liquid soaps, disinfectants, antibiotics, and intravenous solutions. With so many different purposes, it’s essential to choose a filler that can be adapted to meet different requirements. It’s also important for these machines to be tested, approved, and certified by the FDA for the filling of large-volume parenterals.
<h2>Seals and fills infusion bottles, vials, and bags</h2>
With a filling range of 1 to 3000 ml, the BTA by Wick Machinery is a low speed machine that is able to deliver an output of filling 3000, 1500, 900, or 500 containers per hour. This semi manual filler is designed with a peristaltic dosing pump and a separate sealing station for crimp caps, allowing product-specific filling.

Moreover, all parenterals are treated with inert gas, while the model’s swivel arm seals and fills bags or bottles at the same time. BTA further boasts a luer-lock closure, which is a tip cap connected to the syringe that keeps the material inside from drying and curing. Its monochrome touch screen allows further data processing, and the unit can be easily interchanged for vial and bottle filling.

Low speed Filler for large-volume parenterals

In industries where precision and efficiency are paramount, such as food and beverage or pharmaceuticals, achieving consistent fill volumes without product waste is crucial. Traditional methods often lead to inaccuracies and increased costs due to product spillage and container misalignment.
<h2>Accurate filling of liquids with minimal waste</h2>
The Masterfil Automatic Volumetric Filler by Adelphi is designed for precise liquid filling with exceptional accuracy of up to ±0.2%. This system supports fill volumes ranging from 250ml to 30L, making it versatile for various liquid types and container sizes. The filler employs advanced sensors to ensure that containers are perfectly aligned before filling, effectively reducing waste and saving costs. Additionally, the system's 'No container, no fill' feature prevents product wastage and its programmable nozzles can dive and rise, optimizing the filling process for different container shapes and sizes. Constructed with hygienic 316L stainless steel and PTFE contact parts, the Masterfil ensures longevity and reliability even in harsh environments. The machine's capability to store multiple filling profiles allows for quick and easy transitions between different products, enhancing overall production efficiency. This filler is suitable for low to high viscosity liquids and can be ATEX compliant for handling flammable products, making it ideal for sectors such as food and beverage, pharmaceuticals, cosmetics, and chemicals.

Automatic volumetric filler for liquid products

In the production of daily chemical products such as detergents and shampoos, it is vital to maintain precision and consistency during the filling process. Without a reliable filling system, companies may face challenges such as spillage, underfilling, and contamination, leading to costly waste and faulty products.
<h2>Ensuring precise and efficient liquid filling</h2>
The Automatic Daily Chemical Detergent Shampoo Filling System by Alps Machine is a high-tech solution designed for a variety of liquid viscosities. This system utilizes volumetric and piston filling techniques to achieve precise filling volumes from 100ml to 2L, handling capacities between 1000 to 5000 liters per hour. The filling system incorporates a servo motor drive and SUS316L material for the piston to ensure speed and stability. Each filling head is equipped with an air cylinder to provide an anti-leakage function, while the diving system prevents foaming. Users can easily adjust different volume settings to match specific production requirements. Ideal for applications ranging from cleaning liquids to viscous products like tomato sauce and vegetable oil, this filling system ensures high precision with a filling accuracy of +/- 0.5%.

Automatic detergent shampoo filling solution

In the food and chemical industries, precise and efficient oil bottling processes are essential. Achieving accurate fills with minimal waste and contamination poses significant challenges, especially when dealing with varying viscosities and differing bottle sizes.
<h2>Efficient and precise oil filling system</h2>
The Automatic Food Cooking Vegetable Oil Bottling Machine (SNYG-10) by Alps Machine is an advanced liquid filling solution designed for various viscosities. The volumetric filling type allows fast, precise, and stable filling of oils into bottles ranging from 500ml to 3L. The system's servo motor-driven pistons ensure accurate volume settings, and its anti-foam diving system and Airtac cylinder-equipped filling valves reduce leakage and foaming. Operating at a capacity of 2500 to 3000 liters per hour, the machine is suitable for foodstuff, cosmetics, medicines, grease, detergents, and chemicals. The structure and materials, including SUS316L stainless steel, ensure durability and compliance with industry standards.

Automatic food cooking oil bottling solution

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

Producing pharmaceutical, cosmetic, or other liquid products often requires precise filling and secure closing of plastic bottles. Ensuring an effective and accurate method for this process is crucial, especially when dealing with large-scale production where quality and consistency are paramount.
<h2>Automatically sort, fill, and close plastic bottles</h2>
The FVK 50400 is an intermittent motion system by Bausch+Ströbel, designed for fully automatic sorting, filling, and closing of plastic bottles. This system employs a walking beam to gently transport the containers through the work area. It features a dosing station outfitted with four rotary piston pumps, ensuring precise liquid filling. Alternatively, the machine can be equipped with peristaltic pumps. The closing stations can handle droppers, screw caps, snap-on caps, and multi-dose dispensers. This machine offers 100% In-Process Control (IPC) at full capacity and processes up to 10,000 items per hour. Container diameters range from 14.25 to 30 mm, and heights from 30 to 67 mm. The product-carrying parts are sterilizable and autoclavable, maintaining optimal laminar air flow, thus satisfying stringent pharmaceutical standards.

Filling and closing solution for plastic bottles

In the personal care industry, packaging liquid soaps efficiently and reliably in flat pouches is crucial to maintaining product integrity and reducing packaging waste. High-speed and precision filling are necessary to meet production demands and ensure leak-proof packaging.
<h2>High-speed pouch filling for personal care products</h2>
The F-17 by Enflex (Coesia Group) is a horizontal flat pouching system designed for packaging liquid soaps, among other personal care and healthcare products. Capable of handling pouch capacities up to 500ml and operating at speeds up to 180 pouches per minute, the F-17 is ideal for high-volume production environments. Its precision filling technology ensures consistent and accurate product dosing, minimizing waste and reducing the risk of leaks. The system supports various pouch types, including reclosable options, and can accommodate different product viscosities. Additionally, easy-to-use controls and seamless integration into existing production lines make the F-17 a practical choice for manufacturers.

Horizontal flat pouching system for liquid soaps

In manufacturing environments, precise liquid filling is essential for maintaining product consistency and quality. Production lines often face issues with accuracy and reliability, especially when handling varying viscosities and fill volumes.
<h2>Automates accurate liquid filling of various viscosities</h2>
The Filltronic by IMA is a positive displacement gear pump liquid filler, widely used since 1981 for its accuracy and reliability. The system employs sanitary stainless steel precision gear pumps that meter the liquid product into containers through positive shutoff nozzles. With a flexible configuration of 2 to 12 pumps, the Filltronic can reach filling speeds of up to 140 bottles per minute, maintaining an accuracy of +/- 0.5%. It is compatible with a wide range of fill volumes from 0.5 ounces to gallons without the need for change parts. This reduces downtime typically associated with piston fillers. The system features motors with integral precision encoders for individual pump control, ensuring continuous operation even if one motor fails. The Filltronic is equipped with instant recall memories for product setups, providing tool-less adjustments and quick-clean pump and nozzle designs. The control system includes an Omron Sysmac PLC and an 8-inch CTC color touchscreen. This technology is particularly suited for the personal and home care industries.

Positive displacement gear pump liquid filler

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