Aseptic drum filling machine

Types of Aseptic Drum Filling Machines

An aseptic drum filling machine is designed to fill products into containers in an aseptic environment. There are different types of these machines, as provided below.

• Piston Filler

  The piston filler works by using a piston to push a product into a container. The filler process can be done through one head or multiple heads. The machines are advantageous due to their low prices but are still effective. They are great for thick products but may not be so good at filling containers accurately. To achieve a more precise filling, the units may have to work with fewer pistons.

• Servo Piston Fillers

  These units work just like the regular piston fillers. However, instead of a hydraulic drive, they make use of a servo motor. The filler knows exactly how much to fill each container with, so it’s very accurate when filling. The servo piston filler works well with thick and slim products.

• Rotary Fillers

  Rotary fillers can also be liquid fillers, semi-solid, and solid filling machines. They are often used in high-production settings and are ideal for thin liquids. A bottle moves around in a rotary motion, and as it does so, it gets filled up to the pre-determined setting. Because they are mainly used for thin liquids, rotary machines are often used for products like water, soda, and other kinds of juices. They are very fast and efficient, filling up to 1200 containers per hour.

• Vacuum Fillers

  These machines make use of a vacuum to fill products into containers. They are more commonly used to fill liquids and granules into containers. The advantage of the aseptic filling vacuum is that they are very accurate when it comes to filling, and they are also fast. Their speed can be between 600-1200 fills per hour.

Specification and Maintenance of Aseptic Drum Filling Machines

Specification

The following specifications of aseptic drum filling machines have been customized for specific needs.

• Filling Volume: Manufacturing industries offer various models of aseptic drum filling machines with distinct sizes and capacities. These range from 50 liters to 200 liters. Customers can also find machines with 5 to 1,000-liter volumes.
• Filling Speed: Depending on the model and specifications, the filling speed of an aseptic drum filling machine may vary. The speed is usually between 2,000 to 4,500 drums per hour.
• Filling Accuracy:The accuracy of an aseptic drum filling machine is usually ±1% to ±0.5%, depending on the model and manufacturer's specifications.
• Machine Size: Depending on the model and manufacturer's specifications, the dimensions of the aseptic filling machine may vary. The length is approximately 3,000 mm, the width 1,800 mm, and the height 2,500 mm.
• Power Requirements: The power requirements for the machine may vary, depending on the model and manufacturer's specifications. It is approximately 5 to 15 kW.
• Pneumatic Pressure: Pneumatic pressure can vary depending on the model, manufacturer's specifications, and filling requirements. Generally, it is between 0.2 and 0.8 MPa.
• Control System Depending on the model and manufacturer's specifications, the control system of the aseptic drum filling machine may vary. Itisusually PLC（Programmable Logic Controller）controlled and isintegrated with touch screen and advanced software for easy operation and control.

Maintenance

Proper maintenance ensures optimum performance, efficiency, and safety of the aseptic drum filling machine. Here are some of the maintenance tips for the machine:

• Regular Cleaning: It is essential to regularly clean and sterilize the filling parts of the machine. This prevents the accumulation of product residue, bacteria, and contaminants.
• Routine Inspection: Regularly inspect all components of the drum filling machine aseptic for wear, damage, or looseness. Pay special attention to key components such as sealing parts, transmission systems, and control components. Replace or repair any parts as needed.
• Lubrication: Lubricate all moving parts of the machine. This ensures smooth operation and prevents abrasion and damage.
• Components of the filling machine are often in contact with cleaning agents or sterilizing solutions. Ensure that no residue is left after cleaning.
• Pay attention to operating parameters when using the filling machine. Maintain the stability of temperature, humidity, pressure, and other parameters. This helps to keep the aseptic state and ensures product quality.
• Regularly calibrate and test the filling accuracy of the machine. This helps to ensure its stable operation and high precision.
• Establish a maintenance schedule and perform regular maintenance and servicing according to the schedule.
• Use the correct replenishing agent to clean parts of the filling machine that are in contact with food. This maintains the safety and hygiene of the filling machine.

Uses of Aseptic Drum Filling Machines

Aseptic drum filling machines are used in various industries to fill large drum containers of products that require aseptic processing and packaging to extend shelf life and ensure safety.

• Food Industry: An aseptic drum filling machine is widely used in the food and beverage industry to fill drum container of liquid food products such as juices, soups, sauces, dairy products, and processed foods. Filling large drum containers instead of smaller ones is more efficient, especially for products that have to be kept at room temperature and have a long shelf life.
• Pharmaceutical Industry: In the pharmaceutical sector, aseptic drum filling machines are used to fill drum containers with sterile liquids, such as vaccines, medications, intravenous (IV) fluids, and other pharmaceutical products that must be handled in a contamination-free manner. The large drum containers can be used for bulk supply or further processing in more centralized facilities.
• Chemical Industry: Aseptic drum filling machines can be used in the chemical industry to fill drum containers with chemical products, such as agrochemicals, specialty chemicals, liquid fertilizers, and other industrial liquids that require aseptic handling to prevent contamination and maintain product integrity.

How to Choose Aseptic Drum Filling Machines

Choosing the right aseptic drum filling machine can be overwhelming, given the many options available. It helps to understand the needs of the specific industry application before anything. Explain the requirements, including the product to be filled, the container used, the volume, the temperature, and any special features or regulatory compliance that may be necessary. Make a thorough study of the available options. Several machines can fill drums, including piston pump FILLERS, gravity fillers, vacuum filling lines, and servo and pump-based FILLERS with level control. Some are more suited to a particular product's viscosity, humidity, and other aspects.

Evaluate the machine's efficiency in terms of speed, accuracy, and ease of use. It should be easy to set up, operate, clean, and maintain, with clear instructions and minimal downtime. Take a look at the technical specifications. The capacity of the hopper or drum, the filling speed, the type of control system, and any safety features should all be examined to ensure compatibility with requirements. Understand the different types of Aseptic Filling Machines available:

• Volumetric Fillers: They are the most popular types of aseptic drum filling machines, which are based on the measurement of definite volume to achieve accurate filling. For example, gravitation is based on the principle that filling is determined by the weight of the product, which is weighed before and after filling.
• Piston Fillers: They are also volumetric aseptic drum filling machines, which work by pushing the liquid through the nozzles by using a piston-driven mechanism.
• Vacuum Fillers: Differently from piston fillers, they work by sucking liquids into the container through nozzles by using the power of vacuum.

Are unsuitable for certain products, such as those that foam when filled or products that may require more significant precision than 1% error.

The machine should also have safety features like overload protection, emergency stop buttons, and guards to prevent accidents. Ensure the machine can be calibrated to adjust the filling volume and speed to meet different product requirements. It is also important to know whether the machine can be cleaned thoroughly to avoid cross-contamination. The manufacturer's service and support network is also important.

Consider the machine's energy efficiency to reduce operating costs and environmental impact.

Aseptic drum filling machine Q&A

Q1: What kinds of products does an aseptic filling machine handle?

A1: Aseptic filling machines work with a broad range of products, including acidic and non-acidic food and beverages, liquids in the pharmaceutical industry such as syrups and solutions, and industrial products like chemicals, detergents, and agrochemicals. Specific machine parameters and adjustments may be necessary for particular product characteristics.

Q2: Are aseptic filling machines food safe?

A2: Yes, all machines discussed have food-safe compliance with international standards for hygienic design, material selection, and construction. Regulatory requirements from organizations like the FDA and EFSA apply to them. The compliance of each machine with food safety regulations should be verified according to each product.

Q3: Are aseptic machines filling sterile?

A3: Aseptic does not mean sterile. Aseptic means that the product is transferred to a package in a controlled environment and not in a sterile condition. While these machines create a hygienic space for processing, complete sterility is unattainable. They do, however, eliminate viable microorganisms that would otherwise cause spoilage.

Q4: What is the difference between aseptic and sterilization?

A4: Aseptic refers to the process of combining food or other products with pre-sterilized containers in a sterile environment. On the other hand, sterilization is a separate process aimed at killing all microorganisms, including bacteria, viruses, fungi, and spores. As mentioned above, complete sterilization is impossible, but significant reductions of viable microorganisms are achievable.

Q5: Can an aseptic filling machine be customized for different container shapes and sizes?

A5: Yes, Aseptic filling machines can be customized for various container shapes and sizes by altering the nozzle design, adjusting the filling pressure and volume, and modifying the machine's dimensions and controls to accommodate the desired containers.