The tube filling machine is one of the most widely used machines in various industries, used for filling thick liquids or liquids mixed with solid materials and particles, such as creams, cosmetics and hygiene products, paints, and similar items. With these machines, tubes made of aluminum, laminate, and plastic in various sizes can be filled with products. In this content, we aim to explore what a tube filling machine is and later discuss its advantages and how it works.
به طور کلی استفاده از دستگاه پرکن تیوپ سبب افزایش سرعت کار، ماندگاری محصولات، رعایت بهداشت، بسته بندی زیبا و موارد مثبت دیگر میشود. به همین منظور تمامی کارخانه‌ها از این دستگاه برای پر کردن تیوپ‌های خود استفاده می‌کنند.
What is a tube filling machine?
The tube filling machine is one of the most widely used machines in various industries, and its purpose is to fill metal, plastic, or laminate tubes with the desired liquid or mixture. This machine is considered an indispensable component in the cosmetics, hygiene, and pharmaceutical industries.
Tube filling machines have completely different systems based on the viscosity of the desired material, and they are also classified into various categories based on their sizes. Today, we witness different types of tube filling machines for both thin and thick materials, available in home, workshop, company, and factory sizes.
Types of tube filling machines
After explaining what a tube filling machine is, we will discuss its types. In general, filling machines are divided into four categories: tube fillers, can fillers, bag fillers, and cup fillers. Our focus in this section is to introduce the different types of tube filling machines.
این دسته‌بندی‌ها برحسب نوع عملکرد و مکانیسم دستگاه بوده که به سه مدل دستگاه تیوپ پرکن تمام اتوماتیک، دستگاه تیوپ پرکن نیمه اتوماتیک و دستگاه تیوپ پر کن دستی تقسیم میشوند. همچنین برحسب عملکرد نیز شاهد دسته بندی این دستگاه بر اساس پرکن توزین دار و پرکن حجمی هستیم. از دیگر انواع دسته بندی‌های دستگاه تیوپ پرکن برحسب نوع محصول بوده که آن را به دسته‌های بسته بندی پودری، مایعات و پرکن فشاری مایعات تقسیم می‌کنند. حال هرکدام را به طور دقیق‌‌تر توضیح می‌دهیم.
Classification of tube filling machines based on mechanism
- تیوپ پرکن تمام اتوماتیک: این گونه دستگاه‌ها به‌طور کاملاً اتوماتیک پروسه پر کردن تیوپ را سپری می‌کنند و به نیروی انسانی نیاز ندارند. پر کردن در این دستگاه‌ها با تنظیم کامپیوتری صورت گرفته و تمام موارد مورد نیاز از طریق برنامه به دستگاه داده میشود.
- دستگاه تیوپ پرکن نیمه اتوماتیک: در نمونه نیمه اتوماتیک بخشی از کار به طور انسانی و بخش دیگر توسط دستگاه انجام میشود. دستگاه تیوپ پرکن نیمه اتوماتیک در مقایسه با نمونه‌های تمام اتوماتیک ارزان‌‌تر است و سرعت مناسبی نیز دارد.
- دستگاه تیوپ پر کن دستی: پروسه پر کردن تیوپ در این نمونه از دستگاه‌ها توسط نیروی انسانی و اپراتور انجام میشود. بدین صورت که اپراتور تیوپ را در محل مورد نظر گذاشته و پس از پر شدن آن را به دستگاه دوخت دستی می‌برد. این نمونه از دستگاه برای فعالیت‌های کارگاهی با تعداد تولید کم و یا کسب و کارهایی که بودجه اولیه محدود دارند مناسب‌تر است.
Classification of tube filling machines based on the mode of operation
- دستگاه تیوپ پرکن توزین دار: این دستگاه برای کار تنها به پر کردن مخزن موردنظر نیاز دارد. سپس با توجه به برنامه‌های موجود در دستگاه وزن نهایی تنظیم میشود. در ادامه آن با روشن کردن دستگاه شاهد انتقال مواد به داخل تیوپ در وزن تعیین شده هستیم. نمونه تیوپ پرکن توزین دار خود شامل سه مدل تک توزین، دو توزین و چهار توزین بوده که نمونه‌های چند توزین به طور هم زمان وزن موردنظر را در چند تیوپ پر می‌کنند. به کمک این دستگاه میتوان انواع تیوپ‌های پلاستیکی، سلفونی و پلی استری را پر کرد.
- دستگاه تیوپ پرکن حجمی: این نمونه عملکرد کندتری نسبت به نمونه توزین دار دارد و برای پر کردن حجم مشخصی از مواد مورد استفاده قرار می‌گیرد. به کمک این دستگاه میتوان مواد مختلفی نظیر ادویه و حبوبات و یا حتی روغن‌ها و مواد با غلظت‌های بالاتر را بسته بندی و پر کرد.
Classification of tube filling machines based on product viscosity
Another type of classification of the machines is based on the viscosity of the material, which is divided into two categories: thick tube filling machines and thin tube filling machines.
- دستگاه تیوپ پرکن غلیظ: این دسته برای مایعات با غلظت بالا مورد استفاده قرار می‌گیرد که معمولاً شامل نمونه‌های فشاری و پیستون و سیلندر است.
- دستگاه تیوپ پرکن رقیق: دستگاه تیوپ پر کن رقیق برای موادی با غلظت و ویسکوزیته و چگالی پایین مورد استفاده قرار می‌گیرد که معمولاً از نوع ثقلی است.
How tube filling machines operate
The operation of these machines varies depending on the type of machine and the product in question. If you use fully automatic models, the entire process of transferring, filling the tube, and packaging is carried out without human intervention. To operate this machine, you only need to enter the desired program. In the case of a semi-automatic tube filling machine, part of the process is done manually, while the other part is handled by the machine itself. However, in a manual tube filling machine, a large portion of the tube filling process is carried out manually with human labor.
The operation of this machine also varies depending on its type. For example, if the machine is pressure-based, it uses air pressure to transfer the liquid into the tube. If the machine operates with a piston and cylinder, the fluid transfer into the tube occurs through the movement of the piston. If the machine is gravity-based, the transfer happens with the help of gravity and the weight of the liquid itself
Advantages and disadvantages of tube filling machines
Until this point, we have discussed what a tube filling machine is and its various types. In this section, we will review some of the advantages and disadvantages of this machine. In general, the advantages of tube filling machines are so numerous that their significant presence in various industries is evident. One of the benefits of this machine is the ability to fill tubes for cosmetic and personal care products without human intervention, preventing the introduction of microbes and contamination of the product.
Another advantage is its high speed; with this machine, a large volume of product can be filled and packaged into tubes in a shorter period of time. Another benefit of this machine is the reduction in overall costs for a company, as it helps the business avoid the need to employ a large number of workers by investing in just one automatic tube filling machine.
Other advantages of this machine include the ability to design the nozzle with 1 to 8 outlets, depending on the customer’s needs and the production line. The machine also has color point detection capabilities, allowing the level of liquid inside the tube to be accurately measured.
Another advantage is the prevention of product waste, as excess material remains in the machine’s reservoir and can be collected and reused at the end. The benefits of this machine are numerous in various industries, and practically, there are no significant drawbacks to it.
The working mechanism of the tube filling machine
In general, a tube filling machine consists of several components, such as the tube reservoir, tube guide section towards the filler, tube orientation system, filling system, sealing section, and finally, the tube date stamper. These components vary depending on whether the machine is manual, semi-automatic, or fully automatic.
Additionally, its operation varies depending on the type of tube, whether it’s aluminum, laminated, or plastic. In fully automatic tube fillers, the entire process is carried out by the machine itself. This includes placing the tube into the mold, filling the tube to a specified level, sealing the tube’s end, and ejecting it from the machine, all automatically without the need for human intervention.
In semi-automatic models, placing the tube in the designated position is done manually, while the other steps are performed automatically. In manual tube filling machines, a significant portion of the process is carried out manually, meaning operators play a crucial role in the operation of the machine and in filling the tubes.
In general, to use this machine, factors such as the production line capacity, available investment and budget, type of work, and other relevant considerations must first be assessed.
Technical Specifications
These specifications vary depending on the type of product. For example, the design model based on its mechanism is one of the features of the machine, which can either be a complete mechanical mechanism or a pneumatic mechanism.
The troubleshooting system, hack-back system, two-color and three-color filler, water-cooling system, double-wall reservoir, injection mixing, pre- and post-gas systems, various sizes for placing tubes in different dimensions, speed adjustment system, printing adjustment sensor system, the use of hot air to improve sealing quality, and other technical specifications are additional features of these machines.
The machine is made from a stainless steel frame and body, with the ability to detect black spots, the option to place multiple reservoirs in the device, programmability, and the ability to control speed or automatic ejection, all of which are considered features of the device.
Application of the tube filling machine
کاربردهای این دستگاه را در صنایع مختلف نظیر پر کردن پماد، لوسیون، راه اندازی خط تولید کرم، ضد آفتاب، رنگ مو، خط تولید خمیردندان، خوراکی‌های تیوپی نظیر عسل، شکلات، چسب، لاک ناخن، ژل موضعی و… میتوان دید.
Summary
One of the packaging types available in the market for various products such as gel, cream, toothpaste, ointment, etc., is the tube. Tube filling machines are required to fill these tubes.
This machine comes in three forms: manual, semi-automatic, and fully automatic. Depending on the type of machine, the process includes placing the tube, rotating it, filling it with the desired material, sealing, labeling, date printing, and finally, removing the tube. When choosing this machine, it is important to consider the type of product, production volume, production line capacity, and available budget. Overall, using these machines can save a significant amount of time and reduce additional costs for a company.
Frequently Asked Questions
✅مهمترین نکته برای انتخاب دستگاه پرکن تیوپ چیست؟
Some of the most important factors to consider when choosing this machine include the concentration, viscosity, and density of the desired product, the initial budget for purchase, production volume, and the production line. Based on these factors, different types of tube filling machines can be selected.
✅How many types of filling machines are available in the market?
The classification of these machines is done from various perspectives. One type of classification is based on the operating mechanism, which is divided into three categories: manual tube fillers, semi-automatic tube fillers, and fully automatic tube fillers. Another type of classification can be based on the product type or the type of tube, which can be metal, aluminum, laminated, or plastic.
✅Can the components of the tube filling machine be purchased separately?
In general, a tube filling machine, depending on the type of product and the weight of its series, has various tubes and collars, which can be purchased separately and installed at the required location.
✅What components make up a fully automatic tube filling machine?
This machine consists of a reservoir, tube placement section, tube alignment section, filling nozzle, end cap, tube sealing, and, if desired, a date printer.
✅ What are the types of filling machines available in the market?
In general, in the market, we see various types of filling machines such as bag filling, can filling, cup filling, and tube filling machines.