MAKWELL Filling Lines
With significant and extensive expertise over 15 years, we specialize in manufacturing complete filling lines. We are proud in designing and building filling solutions to satisfy the unique demands of both small and large businesses across all major industries.
In addition to our completed filling lines, including the sauce filling line, medical filling line, and daily chemical products filling line, we can customize any filling lines to meet your production demands. From emulsifying machines, mixing tanks to filling machines to capping/sealing machines to labeling machines to case machines, we offer a complete production line to our clients.
Filling Lines
Complete filling line for liquid food production (sauce, honey, mayonnaise, jams, etc.) Emulsifying machine, mixing tank, filling machine, capping/sealing machine, labeling machine, case machine. Filling speed of 15-100bottles/min.
Complete filling line for various medical production (liquids, tablets, powder, inhalers, glass vials, cartridges, syringes, etc.) Isolator system, washer, depyrogenation tunnel, filling machine, capping/sealing machine, labeling machine, case machine.
Complete filling line for daily chemical product manufacturing ( liquid detergent, liquid soap, shampoo, fabric softener, etc.) Filling machine, capping/sealing machine, labeling machine, case packing machine.
Filling Line Advantages
Filling lines can be overall customized depending on manufacturing goals and available space. Suit small to large product manufacturing.
Filling lines are capable of filling bottles or containers of varying volumes and capacities, with easy operation and maximum adaptability.
Automatic product making, filling, capping, labeling, screen memory parameters, container type change, and parameter modification.
Suitable filling systems for various products. Volumetric system for granules, piston pump for liquids, and auger dosing for powders.
What Are Filling Lines?
Packaging products, especially liquids, and other chemicals, require careful handling throughout the filling process. Depending on the product being packed and the kind of packaging used (PET or glass bottles, cans, Tetra-packs, etc.), the process can be carried out in various ways. Each step of a filling line requires a unique set of machinery to accomplish specific goals. The top ones are as follows:
- Emulsifying machine
- Washer/rinser and/or Washer/drier
- Filling machine
- Capping machine/sealing machine
- Labeling machine
- Case machine
Filling Lines Work Flow
- Product Processing/Making System
- Bottle/Container feeding
- Automatic product filling
- Automatic cap feeding
- Automatic aluminum foil sealing
- Automatic bottle labeling
- Automatic inkjet date printer
- Finished product collecting table
Filling Line Features
- It is one of the most innovative and reasonably priced bottle filling lines available today.
- High productivity while reducing labor costs.
- Customized integration services to cater to the needs of various products.
- There is no need for replacement parts. All contact components may be disassembled without the need for tools.
- Compliance with the cGMP standards.
- Feeding trays with two levels of vibration.
- Separate hoppers and vibrating parts on the channel counter.
- Dual-lane, standard hygienic conveyor.
- High-quality stainless steel equipment construction.
- Training and support are available for complete onsite integration, setup, and installation.
What are the Components of the Filling Line?
A filling line has multiple components that all function together. Although they may vary from manufacturer to manufacturer, they have the same fundamental parts. These elements include:
Emulsifying Machine: This device aims to mix the product’s liquid and dry ingredients into a fine, consistent, flavorful whole.
Mixing Tank: This stainless steel mixer machine includes an automated liquid level control system with precise proportional control, flow control, and temperature control. For CIP cleaning systems without dead angles.
Holding Area: This section will hold the empty bottles that will be used to fill the product.
Bottle Feeder: This is the component that places the bottles ready for filling.
Electrical Unit : All electrical components necessary to operate the filling line are contained inside it. Additionally, it powers the machine.
Control Panel: All of the machine’s control components are in this portion. Both a PLC and an HMI are included. From that one area, the operator may simply keep an eye on the filling procedure and input parameters.
Motors: These components are an electrical-to-mechanical energy converter that will power the filling line’s mechanical actuators.
Product Filling Unit: The operator will use this section for filling the product into the bottles or other packaging.
Pump Filler: Fill the bottles using this pump by directing the product to the filling heads. It will control how much liquid product gets into each bottle.
Sensors: These make filling easier. It can identify bottle presence while filling. Waste is also reduced as the system will not fill the bottles if it finds none at the filling station.
Filling Station: This filling machine station is for filling products into bottles.
Filling Heads: This will help in filling the numerous bottles throughout the assembly process.
Capping Device: Following the filling process, this device will attach caps to the bottles.
Bottle Support: This support will keep the bottles in place for the filling procedure to be precise.
Conveyor Belt: It helps guide the bottles as they go through the filling process.
Product Labeler: The labeling machine will apply labels to products or packaging.
Case Packing: The case packer machine will load finished products from a tray or wraparound case’s side, top, or bottom. Following loading the goods, the case is closed and sealed with glue or tape.
◎ Control Panel
An automated device has an intuitive user interface. This contains knobs and signs that are visible. By pressing a button on the control panel, the machine is easier to use. Additionally, it lessens operator accidents.
◎ Automation
A filling line can either be fully or semi-automatic. This implies the machines can run with little to no monitoring from operators. After setting the parameters under which the devices will perform, all that’s left to do is monitor how they do their jobs.
◎ Production Capacity
A fast filling speed on automatic filling equipment reduces effort. Have the capacity to complete many orders quickly.
◎ Design
It has a compact footprint that enables flexibility and simple installation—easily installed inside the industry without the need for a large area.
◎ Material
A filling line’s fabrication materials are primarily stainless steel or aluminum. Apart from having anti-corrosive properties, these materials are also long-lasting. This minimizes the likelihood of needing to replace equipment after a particular time, saving expenses.
To ensure the well-being of consumers, a filling line must meet all applicable international quality requirements.
Among these quality benchmarks are:
✔ Current Good Manufacturing Practice [cGMP] quality standard
A filling line must comply with the following standards of Current Good Manufacturing Practice:
- Maintaining consistency throughout production.
- Meets or exceeds all applicable international specifications.
- Creates effective methods for filling.
✔ Restriction of Hazardous Substances (RoHS)
This standard helps to lessen adverse effects on the environment and human health. It guarantees that the equipment will produce no dangerous compounds while it is in use.
✔ European Union CE marking
Even though it only pertains to the European Economic Areas, this quality standard is recognized by all businesses worldwide
Filling Line Classification
In the liquid filling industry, liquid filling lines using flow-filling machines are extensively used. These devices measure the precise quantity of liquids required by various packaging types, such as bottles, cups, jars, cans, cartons, pails, etc.
This filling line is capable of handling a variety of liquids, including water, carbonated beverages, and alcoholic beverages. It may also fill containers of sauces, salad dressing, soup, oil, liquid detergents, perfume, paint, etc.
Spiral feeding and light control technologies design of powder filling lines guarantee excellent filling accuracy and drip-free operation. It features a filling machine that fills granulated or powdered items with a free-flowing or non-free-flowing consistency.
Powder filling lines handle include granulated sugar or table salt. On the other hand, non-free-flowing items, such as powdered milk and brown sugar. The chemical, cosmetic, and food sectors often use them.
What are the Factors when Choosing a Filling Line?
The selection of a suitable filling line is crucial, and several considerations must be considered. This is because the right filling line will effectively fill products efficiently. The following are some factors to think about before selecting one.
Product Viscosity
The resistance to the flow of a product is its viscosity. Liquids with a lower viscosity flow more quickly, whereas those with a higher viscosity move more slowly.
Filler
This component will help ensure a steady fill rate as you use the filling machine. It may be used for either pulse-based or time-based filling.
Bottle/Container Type
The filling line ideal for your business will also depend on the size and shape of your bottle or container.
Filling Rate
This roughly estimates the bottles you want to fill each minute. In comparison to semi-automated filling lines, fully automatic filling lines can fill more bottles in a given amount of time. They will be more expensive than the semi-automatic models, too.
Filling Volume
use either a liquid-level process, a volumetric process, or a spiral feeding and light control technology to get the product into the bottles.
Holding Tank
Ensure the storage tank retains a sufficient quantity of liquid products without requiring regular refills. You can fill faster using this method.
Quality Standards
Choosing a filling line that conforms to all international quality requirements is crucial. The purpose of these measures is to protect both workers and the final products. It also guarantees the manufacturing procedure’s efficiency, efficacy, and marketability.
Machine Body Material
Choose stainless steel for the filling lines. This guarantees top performance and a long lifespan.
Budget
How expensive a filling line you can afford depends on your financial situation. Select a filling line that works well with your current level of production.
Advancement
Constant developments in technology are occurring. A filling line’s efficiency is dependent on the degree of technology it uses. In addition, enhanced filling methods are now possible because of technological advancements.
Efficiency
Invest in a filling line that guarantees effective filling every time.
Machine Configuration
There are many types and dimensions of filling lines. Get one that fits your workspace well. Larger spaces are essential for commercial filling lines as opposed to home-based ones.
Maintenance
Your business might profit from a simple filling line to fix if anything goes wrong. Also, make sure replacement components are readily available. Additionally, having readily available replacement parts will save delays throughout the filling operation.
A fully autonomous filling line does every task independently, but a semi-automatic system requires some human input. The cost of a fully automated system is more than that of a semi-automatic one. Additionally, an entirely automatic system is more technologically advanced than a semi-automatic one.
When compared to a semi-automated system, a fully automatic filling line may produce more bottles per hour. The system has more precision and productivity while filling than a semi-automatic model.