A filling production line includes bottle making, bottle washing, bottle unloading, filling, capping, labeling/sleeving, post-packaging, palletizing, and conveying processes. It is widely used in the food, beverage, daily chemical, pharmaceutical, and agrochemical industries. The filling machine belongs to the filling stage; it draws liquid from the storage tank and transports it through pipelines to the filling position, filling the bottles until the set volume is reached.
Case Details
Filling - Filling MachinesA filling production line includes bottle making, bottle washing, bottle unloading, filling, capping, labeling/sleeving, post-packaging, palletizing, and conveying processes. It is widely used in the food, beverage, daily chemical, pharmaceutical, and agrochemical industries. The filling machine belongs to the filling stage; it draws liquid from the storage tank and transports it through pipelines to the filling position, filling the bottles until the set volume is reached. Filling machines typically have rotary or linear mechanical structures, and their movements are usually either stationary or following.
Industry ChallengesMisfilling and Incorrect Filling:
Upon arrival at the front end, each bottle is detected by a photoelectric sensor to determine its position and presence. Errors in this sensor detection can lead to liquid spilling outside the bottle or the filling process failing to complete.
Poor Accuracy:
During the filling process, poor pump speed control can cause excessive acceleration at the start of filling, resulting in liquid splashing and loss. Conversely, excessive deceleration near the end can result in insufficient liquid volume.
Intense Competitive Pressure:
Severe homogeneous competition squeezes equipment manufacturers' profits, while end-user demands are increasingly stringent.
Solution FeaturesFiltering Compensation Algorithm: Precise filling without leaks.
Optimized Online Filling Tracking: Following the cam curve, the timing of the filling mechanism's actions is refined. Dynamic and precise filling is achieved through anti-interference compensation algorithms for front-facing photoelectric sensors and position queue access algorithms.
Multi-speed filling minimizes impact and splashing. Utilizing a multi-speed process library, continuous operation at different speeds over arbitrarily set distances is possible. Three-speed and multi-speed filling minimize impact and splashing, improving filling accuracy.
Multiple product solutions help reduce costs and increase efficiency. Zhongping's rich product line includes a two-in-one servo motor that reduces costs while decreasing cabinet space by 49%. Stepper motors and low-voltage servos replace cylinders and ordinary motors, increasing equipment integration and thus improving capacity, flexibility, and automation.
Realizing valueFollowing error ±0.5mm, a 50% improvement over traditional solutions, while also preventing leaks and significantly improving processing stability.
Filling accuracy <±1ml, a 20% improvement in accuracy.
A rich product line with multiple product combinations addresses diverse needs, improving integration, boosting capacity, and reducing material costs.
