For volumetric fillers, each individual fill head may be timed separately. This may simply mean that the nozzle may open for a set amount of time or that a certain time is set for a pump "pulse" (for example, a turn, or fraction of a turn, of a gear in the pump). Keep in mind that an inconsistent fill on a volumetric filler does not mean levels will vary in the bottles. Instead, it means different volumes of product are being dispensed into different bottles. Operators must check the volume of completed fills to determine if volumes are inconsistent and then adjust the necessary fill heads as needed.
1. Machinery Is Not Leveled
To function properly, almost any piece of Liquid Filling Machine
must sit level on the production floor and liquid fillers are no different. Most designs allow for adjustments with simple leveling legs that can help to raise or lower the machine as necessary. Check the equipment with a level and adjust the machine using the legs as necessary. Once level, run a test cycle with bottles under the fill heads to see if the issue has been corrected.
2. Pump Duration or Fill Times Are Off
On fill-to-level systems, product will normally overflow out of the bottles and back to a Liquid Filling Machine holding tank. The pump must remain on long enough to allow liquid to overflow in each of the individual bottles to achieve the level fill. A short pump duration may mean not all bottles are reaching the desired level. The operator can usually perform a visual inspection during a fill cycle to ensure that all containers are reaching the level and the overflow takes place. If not, simply adding some time to the pump duration of an overflow filler may solve the problem. As a side note, operators of fill-to-level systems should also check to ensure that overflow tubes are not submerged in liquid, which can create back pressure and cause havoc with fill levels.
3. Product Pathway Connections
Automatic bottle fillers will pull product from a bulk tank or other supply, with some using a holding tank to supply product to the bottles. The product will still travel through some pathway, via tubes and cylinders, to reach the containers. Operators of packaging machinery experiencing varying fill levels on overflow fillers or varying amounts on volumetric fillers must check the product pathway for leaks. The operator may not necessarily see product seeping from any of the connections. Loose clamps or tubes may allow small amounts of air to enter the pathway, creating the inconsistent fill. Simple check and tighten all connections on the Liquid Filling Machine and run a test cycle to see if the issue is resolved.
Related Reading: Liquid Filling Machine, Paste Filling Machine
, Vial Filling Machine