Piston fillers, also known as viscous liquid filling machines, are among the most widely used filling machines in the market. These liquid fillers, with their easy operation and simple controls, transfer various products from storage tanks, hoppers, and other bulk equipment into large and small containers. The application of piston-cylinder filling machines includes various uses, such as filling all products in precise volumes.
In each filling cycle, the piston draws the product into the cylinder, and when it is full, it pushes forward, transferring the product from the cylinder to the awaiting containers. Stay with us until the end to learn more about the details and unique features of filling machines.
Piston Cylinder Filling Machine
In the liquid packaging process, there are various types of filling machines designed to handle different viscosities of products, different filling sizes, and other variations in packaging projects. The piston filling machine can solve many issues for products with small particles or liquids with high, medium, or low viscosity.
These machines are available in various types with different mechanisms and can be manual, semi-automatic, or fully automatic. With advanced technology, automatic filling machines are capable of providing maximum efficiency over extended periods. The variable speed and adjustable nozzles make them suitable for different types of containers.
The five main components of a piston cylinder filler are:
- Hopper: Holds large quantities of the product for filling into containers.
- Piston: Moves the product from the hopper to the cylinder.
- Cylinder: Has a fixed internal volume to ensure consistent filling levels.
- Valve: Opens and closes to control the flow of the product through the nozzles.
- Nozzles: Distribute the product from the cylinder into the waiting containers.
Types of Piston Cylinder Filling Machines
These machines can be built as semi-automatic or fully automatic. Semi-automatic machines require more operator interaction, such as placing bottles, starting the filling cycle with a manual switch or foot pedal, and removing the filled container after the process is complete. Fully automatic machines operate with powered conveyor systems, tank float indexing systems, and other automated features to minimize operator assistance and simplify usage. The operator only needs to start the machine, select the correct command on the touchscreen interface, while other functions are typically automated.
Application of Piston Cylinder Filling Machine
These machines, due to their exceptional design, have various applications and are used for different purposes.
Thick or thin products
Piston fillers can be used with almost any product, whether thick or thin. These machines provide ideal solutions for sticky products as well as products with large particles, which other types of fillers may struggle to handle. Thick products are drawn into the cylinder by the piston and are expelled during the return stroke. This filling method not only works for thick products, but its open space allows the machine to control fruits, seeds, and other particles in certain products.
Material handling and container sizes
Since the cylinders and pistons of these machines are designed in various sizes, you can use piston filling machines for both small and large containers. However, keep in mind that if you’re using containers of different sizes, you might need multiple piston sizes.
Control of particles in products
Sauces and jams may contain large chunks of vegetables or fruits that can block piston filler nozzles; however, with technology between the cylinder and piston, this issue can be addressed efficiently, which is one of the key applications of the piston filler machine.
Production of accurate volumetric fillers
The fixed internal volume of the cylinder in each filling cycle allows piston fillers to produce a consistent volume of product with each piston stroke.
Features of the Piston Cylinder Filler device
These machines have unique features, which are discussed below:
A range of nozzle types
Semi-automatic piston fillers typically consist of a single filling head, although there are exceptions in some cases. However, automatic versions may include multiple filling heads, and several nozzles are designed to address the needs of specific products. From simple ball valves to diving heads and bottom-up filling, custom nozzles enhance the versatility of piston fillers.
Control of all product viscosities
While piston fillers are ideal for dispensing sticky products and those with large particles, they can also be used for filling smaller products.
Size and different materials of containers
The pistons in the filling machine can vary in size. This means that piston fillers can handle both small and large containers. Additionally, since the heads do not need to apply pressure or seal the bottle neck for overflow purposes, lightweight or fragile bottles may also work with the piston filler. Even unique container shapes can be accommodated in most machines. Just keep in mind that machines that fill both small and large containers may require multiple pistons.
Good particle control
Since the piston filler cylinder is an ideal filling solution for products like jam, jelly, and even some soaps containing particles, smaller grains and particles do not cause issues. However, large pieces of fruit or vegetables in jam or sauce can block certain parts.
Accurate volume
One of the applications of the piston cylinder filler is that when filling various products, the machine automatically dispenses the desired volume into containers. Each time the piston is struck, the same volume of product enters and exits the piston. As the product is pushed from the cylinder into the waiting containers, the volume will not change again. This process enables very precise volumetric filling.
Diverse Container Shapes
These machines operate in a specific way depending on the size of the product. For example, filling machines that work with bottles tend to hold them from the top, while other containers with different shapes are held from the sides.
Details of piston cylinder filling machines
- The stroke length of the piston and the inner diameter of the cylinder determine the filling volume of the machine. Larger cylinders can hold more product.
- You can adjust the filling volume of the machine by adjusting the piston stroke length, usually through a handwheel.
- It is also possible to adjust the speed of the piston movement.
- The size of the hopper can vary depending on the size of your containers. For example, automatic piston fillers will likely draw products from a large source such as a tank.
- The piston and cylinder of the machine are available in various sizes to meet the needs of different projects, which is one of the features of the piston-cylinder filling machine.
Summary
Piston filling machines, thanks to their well-designed structure, provide precise volumetric filling. Piston fillers also allow the packager to fill products in both small and large volumes. The application of piston-cylinder filling machines includes filling products that contain particles or small pieces, such as tomato paste, salad dressing, and some soaps. Piston fillers can be produced in two forms: fully automatic liquid filling machines or semi-automatic machines. This makes these filling machines useful for all types of facilities.
Frequently Asked Questions
✅How does the semi-automatic piston cylinder filling machine work?
They need more interaction with the operator, including the following:
- Placing the containers inside the machine
- Starting each filling cycle via a hand or foot switch
- Removing each filled container after each filling cycle
They can be offered in desktop versions for smaller packaging.
✅ How long does product packaging take?
It varies depending on the fill volume, liquid viscosity, and the level of machine automation. For example, volumetric filling machines can fill volumes ranging from 5 milliliters to 25 liters at a rate of up to 150 containers per minute.