Viscous gel filling machine

Types of viscous gel filling machines

A viscous gel filling machine is used to fill jars, bottles, and other containers with gel-like materials. There are several types of gel filling machines that can accurately fill products with varying viscosity levels.

• Piston gel filling machine

  This machine uses a piston to push gel products through a nozzle and into containers. Piston gel filling machines can be used to fill both hot and cold gels. However, they are usually better suited for cooler products. These machines can be used to fill products with any viscosity, including thicker gels. No change parts are required to fill gels of different viscosity levels. These machines are ideal for filling 5 to 1,000 ml.

• Vacuum gel filling machine

  A vacuum gel filling machine uses a vacuum to pull gel products into a container. The pressure created by the vacuum will force the gel through the filling nozzle and into the container. This type of machine can fill products that are thin to moderate in viscosity. Vacuum gel filling machines are more economical than piston gel filling machines, and they are often used to fill products like water, vinegar, and cleaning solution.

• Fume orifice gel filling machine

  This type of machine is better suited for filling jars and bottles with gel products that have chunks or are not uniform in consistency. A fume orifice gel filling machine will use a nozzle to squirt the gel product into the container. The nozzle will be inserted in the container, and a predetermined amount of gel will be dispensed. These machines are ideal for industrial applications and usually cost more than other types of gel filling machines.

• Gravity gel filling machine

  A gravity gel filling machine uses gravity to fill gel products into a container. This is done by lowering the gel product through a nozzle and into the container. These machines are popular because they are inexpensive and easy to use. Unfortunately, they are not very accurate, so they are maybe best for using on gels that do not have an established price point.

Specification and maintenance of viscous gel filling machines

Specifications of viscous gel filling machines

The specifications of filling machines vary depending on the type and specific features. The following are some common specifications to check before purchasing.

• Filling range: The amount of gel that a machine can fill in a container is represented in milliliters or ounces. Different machines have different filling ranges. For example, a small machine may have a filling capacity of 10 ml to 1000 ml.
• Gel viscosity compatibility: The machine's ability to work with gels of varying thicknesses is indicated by its compatibility with gel viscosity. Some machines are made to handle gels of varying viscosities, while others are restricted to those with a specific viscosity.
• Accuracy: The machine's accuracy indicates how precisely the gel is filled into the container. It is typically represented as a percentage, with higher numbers denoting more accuracy.
• Speed: The machine's speed is the number of containers it can fill per hour or minute. Depending on the kind and application, this may change. A machine's production would be more suited to high-volume manufacturing than a machine with lower speed.
• Pneumatic or electric operation: These machines may have different methods of operation, such as pneumatic or electric operation. While some machines may be suitable for electric operation, others may be more suitable for pneumatic operation.

Maintenance tips for viscous gel filling machines

To ensure that the gel filling machine works in pristine condition, perform regular maintenance. Here are a few maintenance tips highlighted below:

• Frequent cleaning is one of the maintenance tips for gel filling machines. This helps to maintain hygiene and prevent product contamination. After every fill, wash out any excess product and sterilize the machine. Also, follow the manufacturer's guidelines, especially when handling crucial parts of the machine.
• Secondly, inspect the machine regularly for signs of wear and damage. Gel filling machines are often used in manufacturing lines. Regular inspecting may help to spot operational faults and damages early to extend the parts' lives.
• Thirdly, lubricate moving parts of the gel filling machine to reduce tear and wear and improve efficiency. Lubricating the machine's moving parts prevents overheating, which may reduce product quality.
• Lastly, ensure the gel filling machine is stored properly when not in use. Typical storage methods involve putting the machine in a cool, dry place away from direct sunlight or heat sources. Proper storage protects sensitive parts of the machine from environmental damage.

Applications of Viscous Gel Filling Machines

Viscous gel filling machines offer many applications across multiple industries mostly due to their flexibility, efficiency, precision, and speed. This machine is an essential part of manufacturing processes in the pharmaceutical, food, beauty, cosmetic, and chemical industries, among others.

In the pharmaceutical industry, viscous gel filling machines are used to fill liquid gels into capsules. These machines can accurately dispense gel formulations that vary in viscosity.

Many food manufacturers use viscous gel filling machines to fill their products in an efficient and hygienic manner. They are particularly useful when filling viscous products such as sauces, jellies, honey, ketchup, and jams. These machines ensure consistent volumes and avoid overfills and underfills.

In the beauty and personal care industry, viscous gel filling machines are used to fill products like lotions, creams, gels, shampoos, conditioners, and other cleansing products. With different viscosities for different products, these machines are essential to ensure an accurate fill.

Gel filling machines are useful in the industrial and chemicals sector when dealing with products that have a thick consistency, such as adhesives, lubricants, and chemicals. These machines help improve productivity and maintain service.

Overall, a viscous gel filling machine is useful for manufacturing any product with a thick consistency. The machine improves efficiency and maintains accuracy in manufacturing lines.

How to Choose Viscous Gel Filling Machines

To select the appropriate viscosity liquid filling machine for specific needs, several key features and functions should be considered.

• Container Compatibility

  Product bottleneck, height, and mouth area should be analyzed to ensure proper fitting and functioning.

• Nozzle Type

  Different types of nozzles (like drench, straight, or custom) work better for particular products.

• Accuracy and Reliability

  Examine the machine's count per minute (CPM) and the percentage of fill weight to determine its accuracy, measuring the scale to ensure consistent and precise filling of gel products.

• Adjustable Filling Speed

  Look for controllable CPM to customize the speed according to product viscosity and employee efficiency.

• Product Viscosity

  Select machines designed for specific viscosities, from thin liquids to thick gels, to match product characteristics.

• Production Volume

  Based on the desired quantity of fills per day, pre-determined under a 24-hour production schedule, select machine size and speed to meet the requirement to avoid employee overtime.

• Automation

  Depending on the target worker headcount and operating budget, choose between automatic, semi-automatic, and manual models to determine the level of automated filling.

• Temperature Control

  For products requiring specific temperature conditions during filling, look for machines with this capability, such as cooling jackets or heating elements.

• Ease of Cleaning

  Select machines with cleanable gel filling system parts for quick and efficient maintenance to ensure proper functioning and hygienic practices.

• Data Tracking

  Look for machines that provide metrics like the number of fills, percentages, and other relevant data to monitor production performance.

• Training Requirements

  Consider the employee training needed to operate the machine safely and effectively to ensure proper understanding and minimize risk.

FAQ

Q1: How to choose a proper gel filling machine for one's need?

A1: Consider the machine's capacity, the viscosity of the product to be filled, the type of container, and the desired accuracy and efficiency.

Q2: Can a viscous gel filling machine be cleaned and maintained?

A2: Yes, but the cleaning and maintenance processes may vary depending on the machine model. Always follow the manufacturer's guidelines

Q3: Are there automation options for gel filling machines?

A3: Yes, many gel filling machines offer automatic or semi-automatic models for more efficient and streamlined production processes.