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5 Reasons to Use an Automatic Glass Bottle Filling Machine
Glass bottle is the most commonly used type of bottles for wine, juice, and other drinks. They are being used in a number of different industries for decades. This is when Automatic Glass Bottle Filling Machine comes into play, with its immense importance in the beverage industries.
In this article, we have brought together different reasons to use an automatic glass bottle filling machine. Keep reading and you will understand the reason behind its great industrial demand.
Let's start from the very introduction of the filling machine.
Introduction to Glass Bottle Filling Machine
Glass Bottle Filling Machine automates the bottle filling process in a beverage company. It is a technologically advanced way to make the process less time consuming, and the business more productive.
Automatic Bottle Filler equipment makes it possible for businesses to fill bottles easily and quickly. They help in avoiding unnecessary mess and waste during the process of filling. Food and beverage companies can package their liquid rapidly, and with accuracy.
The machine comes with different speeds, so you can save as much time as you want. The speed and flexibility of this equipment are among its most significant advantages.
Liquid Automatic Filler Machine can be extremely beneficial for businesses. It can fill more than 80 bottles per minute, hence, no more struggling with meeting deadlines.
The flexibility of an automatic bottle filling machine allows for a smooth operation regardless of the bottle size. It allows you to control its speed and can process bottles with different heights, making it extremely convenient.
This equipment is designed to maximize your company's output and accelerate productivity and growth.
Here was a brief introduction. Now, let’s move to the importance of the filling machine in the manufacturing business.
Importance
Automatic bottle filling machines are essential tools for the packaging process.
Beverage packaging industries witness significant gains from automation of the packaging process.
Filling machines are used primarily for food and beverages. But they can be used for packaging of other products, too. Depending on the product, you can use them to fill a bottle or a pouch.
The vast product features make filling machines highly flexible and a valuable investment for packaging businesses.
They are especially helpful for bulk fillings. Handling bulk fillings manually takes way too long and often results in spillage and waste. You can avoid this with an automatic filling machine. For these reasons, Automatic Bottle Filling Machines are in high demand in modern industries.
Other significant characteristics are consistency and precision in filling. Then there is the ability to handle a variety of bottles and products, which increases the importance of this machine.
This much flexibility in an equipment is a great plus for manufacturers.
To clear your perspective about the machine further, we have listed some other benefits it offers.
Benefits
There are a lot of benefits of using an automatic glass bottle filling machine. Those are given down below.
Upgradable
One of the most significant advantages of automatic filling gear is its upgradeability. It works better when correctly integrated as the firm grows. In many circumstances, simply planning while assembling can give the liquid filler space to enhance with the firm. As a result, you can upgrade the machine according to the increased number of filled products required.
You can change components such as alternative nozzles, neck guides, and more. It also helps to adjust product lines in the future.
Most industrial filling machines have four to six filling heads. Though, you don’t need to replace the machine every time your company’s requirements advance. You can modify the same machine if manufacturing demands more assistance.
The number of filling heads depends on the model. you can upgrade that gradually.
Some models allow a maximum of sixteen fill heads.
Easy Operation
The automatic bottle filling machine also allows ease of operation, which makes it much more reliable. It is much easier to use than other bottling machines. You can handle the machine effortlessly, without any learning or difficulty. Some machines also include touch screens for easier navigation while choosing the operations.
At first appearance these liquid fillers may appear complicated to handle. But there operating systems are simple with easy to use tools. However, some bottling machines may require minor changes to shift from one bottle to another.
Some types of the machine use rotating fillers, enabling more manageable and highly automated operation.
High Speed
As compared to manual filling, automatic filling machines work much faster. The speed along with the number of fill heads determine how fast and how many bottles the machine can fill. A machine with sixteen fill heads can fill 120 bottles every minute on average. This translates to thousands of bottles filled each day.
Diverse Filling
Filling machines do not just bottle the same product in the same container. They can fill any product in bottles having different measurements. You need to adjust the machine’s settings according to the measurements.
These machines can work for both thick and thin liquids. This is particularly advantageous for firms with several lines of production.
Consistency
Hand-filling containers results in variations in the amount of product that goes inside, which is inconsistent and unprofessional. The quantity must be same in every bottle and the liquid should not pour to the brim while transferring the items. Measuring instruments might seem helpful, but their use will stifle production.
Liquid filling devices guarantee that each bottle gets filled with the same amount of liquid.
They function in a cycle in which the product is accurately and evenly distributed. This is done while taking into account the volume, weight, level, and other input measurements.
Market Demand
Industrial bottling machines are standard pieces of equipment. They contribute considerably to the beverage industry's manufacturing lines.
Water, juice, wine, and beer are just a few bottled beverages that can be filled with these devices. There are multiple ways to keep the costs down.
Water production and bottling is a labour-intensive and time-consuming operation. Numerous obstacles and investments come with running a business, regardless of its size. Bottling machines are the unique approach to automate this operation.
Numerous choices allow you to select a machine with a unique design. Its goal is to help you stand out from the competition.
Traditional bottle fillers are less productive and inconvenient compared to automatic bottle fillers.
You might find the price of the machine too much at first, an unworthy investment. However, you will get a return on your investment once production picks up.
Purchasing this much needed equipment is one step closer to better success if you can project the expansion of your business.
Here are some reasons why you should buy a glass bottle filling machine.
Reasons to Choose a Glass Bottle Filling Machine
Many consumers fail to see substantial reasons of investing in automatic filling machines. However, there are plenty of reasons. Whether you're setting up a bottle beverage plant, or starting up a beverage packaging company, you'll need this machine.
For a better understanding and to clear your doubts, below are the reasons to choose an automatic glass bottle filling machine.
Handles Different Types of Fillings
Using a different machine for every product is not always a wise idea. Sometimes, a multi-purpose filling machine becomes a dire need for a company. Even if it costs you extra bucks, it will save you the fuss of using different machines to complete the filling process.
A multipurpose filling machine offers great versatility. It is adaptable and flexible, hence able to handle a variety of items at the same time.
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You don't need to purchase multiple filling machines for various commodities. The investment in a multipurpose one is well worth it.
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Sometimes, after going through the settings of a bottle filler, it can be altered to handle different types of bottles and products. But altering the settings is not easy and hassle free in all the filling machines out there.
Automatic filling machine saves you from fiddling with such settings. It saves a great deal of your time and energy.
Reliable Filling
With an automatic filling machine, consistent filling is achievable regardless of the type or size of the bottle. It makes the procedure of filling bottles easier and precise. Furthermore, different types of liquids are filled in accurately and smoothly.
The efficiency and smoothness of every cycle remain unhindered by any criteria. Whether it’s type of the bottle or the liquid, effective performance is guaranteed.
Cost-Effective
The cost-effectiveness of the bottle filling machine is another major reason to buy it. For the vast benefits it offers, this equipment is reasonably priced. Any small or large bottle beverage company can comfortably buy it.
Along with the price, the maintenance costs are also easily manageable. It means you won't have to spend a lot of money on its upkeep. Not that it demands frequent maintenance though.
Increased Lifetime
Even in long manufacturing cycles, industrial fillers are engineered not to break down. Your company can count on them for a long time. Plus, with thorough monthly maintenance checks and with a devoted staff, the machine can serve you for even longer.
Adjustable Speed
The automatic bottle filling machine's speed is adjustable. The machine will work ideally whether your production demand is low or high.
You have the option to change the pace at any time. The power conveyors will adapt according to the parameters. This function is ideal for businesses that have to maintain a high output level.
Also, you won't need to hire labour to increase your output if you have this machinery. It can quickly and efficiently fill each bottle without spilling the liquid.
Tips for Choosing a Glass Filling Machine
The different options you can come across while choosing a filling machine can be baffling. The buying process can be complex and intimidating. Especially If you're new to the world of packaging and automation.
We are here to help you with that too.
The first question to ask is what is the type of bottles or goods you need the machine to fill. Then there are the liquid viscosities to keep in mind.
It’s also wise to seek advice from a reputable and experienced glass bottle filling machine manufacturer.
Follow these tips to obtain the most suitable machine for your needs.
To further help you get the right machine, below are the other important tips. Continue reading and these will help you make the right decision.
The Reasonable Price
When purchasing equipment, considering budget is critical. The company should not experience loss after buying the machine. And it’s not difficult to get a high-quality, low-cost equipment that offers good results.
Accuracy
When it comes to bottling, accuracy and time are crucial. A high-quality machine saves time while maintaining high accuracy. The machine should be able to do a good amount of work in a short amount of time.
The right machine has high-quality filling and cap feeding and a superior sorting system that makes the job quick and precise.
Air Transmitter
With technological advancements, the air conveyor with a track wheel can easily adjust the size of bottles. The process is simple, thanks to the automation system. Choosing a machine of this calibre allows you to accomplish more in less time.
Adjusting such a machine's height according to the bottle sizes will not be a problem.
Superior Quality Steel
The quality of the material of the machine is also important to consider. The material should be high quality stainless steel. It will make your machine corrosion-resistant, strong, as well as long-lasting.
The material of the machine should also be simple to clean before and after use. It is important for hygienic purposes too. To keep any contamination out of the bottles and products when they are being filled.
For some products, more than one machine may be appropriate. However, taking into account the bottle or container in question.
It can assist in making the best decision for specific projects. A client utilizing a transparent glass container would use the level filler, ensuring that each container has the same liquid level.
When exhibited on shelves in a store or supermarket, a glass bottle creates an appealing presence.
Other items may utilize large or tiny containers, impacting the machine or nozzles that you will use for packing.
Aside from the product itself, the packaging you use can assist you in finding which liquid filling machine is suitable.
Conclusion
Hence, an automatic glass bottle filling machine offers simple operation and ease of use. All that while ensuring speed during the process. It makes efficient filling of liquids into bottles with minimal waste possible.
You can also discover more about automated filling machines: various filling concepts and other such instruments.
Contact us to learn more about the advantages of automated bottling equipment.
Production of PET containers requires injection molding of preforms and subsequent stretching and blowing of these into bottles. Both operations can be combined in one machine (the single-stage process) or in two (the two-stage process). Both processes have their distinct advantages and disadvantages, and bottle producers and brand owners would be well advised to know those in order to make the right choice for their products.
The advantages of single stage are:
• Blemish-free bottles;
• Transfer ring not necessary;
• Control over preform production;
• Good conditioning possibilities for oblong bottles on
some machines;
• Thread start can be chosen to coincide with bottle shape;
• Compact and flexible.
In my view, these advantages makes this process a no-brainer for all non-beverage containers. However, there are some disadvantages as well, including:
• Long cycle times;
• Long changeover times;
• Uneven wall distribution;
• Quality problems with thermal-gated hot runners (valve gates
are available and recommended);
• Need to run machines run 24 hr/day to avoid higher scrap percentage;
• Longer learning curve for operators, as two processes and PET drying must be mastered;
• Inefficient blow station as the injection station always has precedent over the cycle time.
The latter issue has led to a subcategory of single-stage machines that I call integrated two-stage machines. These machines feature a multiple of two or three injection cavities per blow cavity, and the blow sections of them cycle two or three times for every injection cycle. This saves blow cavities and thereby reduces tooling costs, a critical issue for small- and medium-volume applications.
The uneven wall distribution is a result of viscous heating of the melt. As the melt moves through the barrel and hot-runner channels it heats up unevenly. When it is then divided into two streams (left and right, typically), warmer material flows to the back of the new channel. If you were to stand in front of the machine you might notice that finished bottles are often thinner at the back because they were blown with warmer material in the back panel.
While PET is very good at self-leveling (the strain-hardening effect that compels initially warmer areas to blow out after cooler areas have blown), this effect is not significant enough to mask the uneven preform heat. A variety of measures have been employed over the years with varying success.
Most hot runners are also not naturally balanced. Natural balance means that the path of the melt to each cavity has the same length and number of turns. Because of geometry—all preforms in one row—this is often not possible, and as a result, preforms do not fill at the same speed, aggravating the problem. Changing nozzle diameters to allow slower-moving melt through larger openings is helpful, but usually can only be optimized for a very narrow weight range. Another solution is to add obstacles in the flow path of the faster-moving cavities.
Thermal-gated hot runners are inferior to valve-gated ones, in my opinion, but most machines still run with the former.
Now let’s look at the advantages of the two-stage process:
• Scalable from 1000 to 72,000 bottles/hr;
• Fast cycle times;
• Fast changeovers;
• Flexibility (preforms can be made elsewhere and stored);
• Very good wall distribution for
round bottles;
• On average, lower gram weights possible for round bottles;
• Process can be stopped at any time.
With two-stage, the main disadvantage is the potential damage to the preforms that occurs when they tumble onto conveyor belts and into storage containers, and then again when they are dumped into the hoppers of blow molding machines. Many of the little nicks and scratches can be stretched out when high stretch ratios are used. But this is not always the case, particularly when a preform is chosen from a vendor and does not exactly fit the bottle to be blown. Wrap-around labels or sleeves are a good way to hide these marks, which is one reason they are so popular nowadays.
A lesser known problem with low-cavitation machines is that heat to each preform can be quite different when indexing machines are used. In these machines, two, four, or six preforms are loaded and blown together. A chain indexes them around the oven system.
Preforms are exposed to varying temperatures inside the ovens because of differences in lamp output and exposure to cooling air. This translates into different preform temperatures from cavity to cavity, and adjusting a process to suit them all can be quite a challenge. There are now a number of linear machines available that move preforms continuously and avoid most of these issues. Rotary machines of course do not have this problem at all, as each preform gets identical heat.
Today, more than 80% of all bottles produced are for beverages, and the vast majority of these are made using two-stage technology. It is the remaining 15% to 20% where either process is an option. Many decisions are actually driven by tool prices. Buying even a four-cavity single-stage tool can be hard to justify for volumes of fewer than 2 million/year, which many of the custom applications are. There is less capital expense involved to buy preforms and run them on a two-cavity reheat machine. The number of available preforms has increased dramatically over the last 10 years with suppliers spanning the globe, because preforms, unlike bottles, are cost-effective to ship.
In order to make an informed choice on which process to use, you need to understand the particulars of the application and make your decision either on the basis of bottle features or economics. If your bottle must be blemish-free, oblong in shape, and with a fixed thread, single-stage is the way to go. If none of those applies, the economics must be scrutinized. The preforms for single-stage are always custom-made (unless you plan to make a variety of shapes out of the same preform) so the fit is guaranteed. If preforms are bought however, the quest for the right one starts. Not every preform that has the right neck finish and weight is suitable for a particular bottle. An expert should evaluate the available preforms and choose the best fit.
Let’s look at a hypothetical application involving a round 1-liter bottle with a 33-mm neck finish and a weight of 42 g. The yearly volume in this scenario is 750,000 bottles. In two-stage, this will require a one- or two-cavity machine that will probably run around 600 to 800 bottles/cavity/hr. While machine builders publish much higher numbers, most custom applications run slower for a number of reasons. This will keep the one-cavity machine busy for 1152 hr, and the two-cavity for half of that. Capital cost is quite low as only one or two blow cavities have to be purchased.
In single-stage, cycle time will be about 13 to 16 sec—say 250 cycles/hr. A two-cavity system would then make the required bottles in 1500 hr, a four-cavity system in 750 hr. Capital cost is significant for each cavity, and of course, most machines will be able to run four or even six cavities. Here the decision would be based on cost per piece in different cavitations, and what future outlook the job holds.
ABOUT THE AUTHOR: OTTMAR BRANDAU
Ottmar Brandau has been working in the plastics industry since 1978, and is the president of Apex Container Tech Inc., Wasaga Beach, Ont. His latest book, The Rapid Guide to Perfect PET Bottles, describes 30 common problems and their solutions. It can be found at blowmolding.org/shop. Contact: (705) 429-1492; info@blowmolding.org; blowmolding.org.
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