Positive Displacement (PD) Fillers utilize a PD Pump Head for each fill head. Using a superior PLC Control Package allows the operator to control each individual fill head with exacting repeatable accuracy using encoding technology for fractional control of the pump head all with an easy to use visual display. The PD Pump Heads are manufactured from high quality S.S. Components and are available in 4gpm and 10gpm options. This filler is designed for higher viscocity products or when a high degree of accuracy is required. This filling machine is versitile enough to handle a wide range of container sizes, fill volumes, and product types making it perfect for almost any application.
Accutek's positive displacement filling machines are best suited for filling viscous products, but they can be used to fill thin products as well. These fillers can handle a wide range of container sizes, fill volumes, and product types; but they are most ideal for filling pastes, creams, lotions and gels, in large volumes and at greater speeds than otherwise achieved with a piston filler. Some example products our positive displacement filling machinery can fill are: heavy sauces, tooth paste, honey, wax, cosmetic creams, heavy shampoo, hair gels and conditioners, and paste cleaners. Cleaning is a simple process, no tools are required. All of our positive displacement filling machines are based on heavy-duty stainless steel frames with all contact parts made of food grade materials.
• The PD series filling machines are based on the VOLUMETRIC FILLING PRINCIPLE. Volumetric fillers deliver a pre-measured volume of product to each container, and the volume of product in each container is held constant.
• The advantages of PD volumetric fillers include accuracy, flexibility, and reliability in addition to being relatively easy to clean. Accurately delivering a pre-measured volume of product to each container also produces cost savings by reducing the amount of product that is used in overfill in some operations to assure that each container receives at least the minimum desired amount of product.
• The flexibility of volumetric filling systems allows them to be adapted to fill a wide variety of products ranging from thin alcohol to thick caulking compounds. They can be used to fill rigid containers or lightweight containers that may be distorted by the forces of vacuum or pressure used in some filling operations.
• These systems are reliable and easy to maintain, because they are constructed from relatively simple design. Volumetric filling systems are relatively easy to clean by flushing techniques since they normally do not have small hoses, tight passageways, or delicate sensing mechanisms that can be clogged or damaged by water or air pressure.
• Using a Programmable Logic Controller (PLC), Touch Screen Operator Control, and Motor Encoding technology, the PLC can control the pump head revolution to a fraction of a revolution.
Positive Displacement Volumetric Filling
• PD fillers measure and deliver the product into the container by utilizing a PD pump head. The standard types of pump heads used are Gear Pump Heads and Flexible Impeller Pump Heads. A Pneumatic Clutch couples the Drive Motor to the Pump Head. A high-speed counter provides feedback to the PLC by counting fractions of revolutions of the motor rotation.
• The Operator programs the PLC to control the amount of product delivered to the container using a “Teach” mode. After the PLC is programmed, the PLC will disengage the motor through the clutch shaft coupler from the pump head, immediately stopping the flow of product into the container.
• With Increased motor control through superior electronics and technology, the pump motor can be programmed to change speeds throughout the fill. The pump motor can be programmed to rotate slower in the initial portion of the fill to eliminate splashing and excessive foaming, speed up during the majority of the fill cycle and then slow again at the end of the fill so the container can be filled close the neck and capacity of the container without splashing, foaming, or overflowing.
• The filling speed is dependant on four factors:
• The pump size rated in either 4 or 10 gallons per minute
• The product type and options such as diving heads in use or required
• The size of the container, or dose size
• The conveyor speed
• Pump heads are selected in two fill rate specifications: 4 gallons per minute (4gpm) or 10 gallons per minute (10gpm). The pump rating will be determined primary by fill speed requirements.
• The two types of PD pump heads that are utilized are Gear Pump Head and Flexible Impeller. The pump head selection is dependant on the product to be filled. The Gear Pump is utilized for thicker or higher viscosity products such as shampoos, greases, any heated or very cold products, or higher sanitary requirement products. The Flexible Impeller Pump is used for items thinner or lower viscosity items, products that do not require high sanitary requirements, abrasive products or products with small-suspended solids or small particulates. The pump head bodies, gears, and impellers also come in a wide variety of materials for chemical compatibility and sanitary requirements.
• Different types of products require different nozzle designs and sizes. The nozzles used for filling an ampule with 10cc. of thin fluid obviously would not be appropriate for filling a five-gallon can with paint, and there are numerous sizes and shapes available between these two extremes.
• The diameter of the nozzle should be selected to provide a smooth flow. If it is too small, the velocity of the material will be too high as it enters the container and there may be splashing and foaming. If the nozzle is too large, the product may drip at the end of each fill. When the nozzle diameter matches the surface tension of the product, a film or bubble is naturally formed in the tip of the nozzle at the end of each fill. This keeps any material left in the nozzle from dripping out. If the nozzle diameter is too large, the film cannot form and there may be a few drips at the end of each fill. This can make it necessary to either run the process slower so that all the drips are caught in the container or to require frequent cleaning of the containers and the machine.
• Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. Some nozzles direct the flow downward in a solid stream; others break it up into a spray, or direct it to the side of the container so that it will run down the sides. Screens may also be mounted inside the nozzles to break up foamy products so that they will flow smoothly. Kiss Packaging Systems has a large selection of nozzles available, and not any one of them is appropriate for all products. The best way to select a nozzle for filling a new product is laboratory testing with a number of different types of nozzles to find the type and size that works most efficiently and effectively. Using an improper nozzle can cause slow operation, loss of product, uneven fills, and a messy machine.
• Some options that will also assist in proper filling are:
Positive Off Nozzles. Positive Off Nozzles have a moving nozzle tip that opens either into the body of the nozzle or extends out of the nozzle. At the end of the fill cycle the nozzle tip is moved so it seats against the nozzle body and stops any potential product dripping. These nozzles must be used in conjunction with diving heads as the flow of product is diverted and if the nozzle is outside the container, product will shower the container.
Positive Shut Off Nozzles. These special nozzles have a piston in the body of the nozzle. These nozzles are used for products that may string or drip. At the end of the fill cycle, the piston extends through the body of the nozzle, evacuating any product that is remaining in the nozzle. The use of the Diving Head option is normally not needed because of the product container neck size.
Diving Nozzle Kit. The diving nozzle kit is an upgrade that is used for products that cavitate, are foamy, or “pillow”. The nozzles will dive into the container and fill from the bottom up allowing for a smooth fill with no overflowing. The nozzles slowly rise during the fill cycle so excessive product doesn't collect and drip. The diving nozzle kit also includes a safety shield to increase the safety for the operator. When the door to the safety shield is opened, the diving nozzles automatically raise and the filling cycle is paused.
Product Drip Tray. This option allows for a drip tray to extend under the nozzles after the fill cycle, allow time for the containers to leave the filling work area, and retract for the next filling cycle. The Drip Tray is controlled by the PLC and will not slow down the fill cycle speed. A reservoir located in the corner of the drip tray allows for the excess product to be drained. This option will ensure no drips fall on the containers causing stains or excessive mess.
Heated Package. A Heated Package upgrade can also be used on the PD Series Fillers. The heated package will maintain the temperature of a pre-heated product while being filled. This is usually only used for products that tend to harden or congeal as they cool down. A variable temperature heat element can be used for the hopper, pump heads, or the nozzles.
Neck Locator. A Neck Locator Assembly is used when odd shaped or unstable bottle are being filled. After the containers are counted in the neck grabber will extend centering and trapping the containers between the neck grabber and a backing bar ensuring that the containers are centered and stable prior to the fill cycle starting.
The Neck Locator and Product Drip Tray are included in the price of the unit if the product and containers warrant the option. If the application does not warrant the options they are not included unless specifically asked for.
Automatic Bottle Indexing
• Automatic models are manufactured standard with a heavy-duty stainless steel, height adjustable base, a 10' long, 4 ½” wide, variable speed conveyor, sanitary style with raised conveyor belt, and an automatic bottle-indexing unit.
• The heavy-duty stainless steel base is standard with four height-adjustable, articulating feet but can be upgraded with heavy duty, locking casters for easy movement. The machine can be moved from one filling line to another in a matter of minutes to accommodate different existing container, labeling, and capping setups.
• The 10' variable speed conveyor can be upgraded to a 15' or 20' variable speed conveyor to allow for auxiliary equipment such as cappers, labelers, safety sleeve placers, heat tunnels, or induction sealers to share the conveyor with the filler. This solves the problem of equipment that does not come standard with its' own conveyor, matching speeds with numerous conveyors or transferring containers from one conveyor to another. The conveyor can also be upgraded to a 6” wide conveyor to handle larger containers. For taller containers, a double rail guide option is available. The 8 and 10 Auto PD Fillers come standard with 6” wide conveyors and double rail guides. The conveyor chain is normally Delrin, a chemical resistant, food grade plastic. The conveyor chain can be upgraded to Stainless Steel in case of higher sanitation needs, chemical compatibility, or when using a heat tunnel.
• Automatic PD fillers come standard with an elevated on board Surge Tank. This allows the pumps to draw directly from the bottom of the Surge Tank eliminating product waste, priming issues, and manifold use. A liquid level logic kit for the Surge Tank is also standard with the machine to use in conjunction with a pump that moves the product from a bulk mixing or processing tank to the Surge Tank. The pneumatic or electronic logic kit will control a valve assembly responsible for allowing an auxiliary pump to fill and maintain the level in the Surge Tank by starting and stopping the pump or controlling a valve. The auxiliary pump is also an available upgrade option.
• The Automatic Bottle Indexing (ABI) System may also be upgraded. All the sensors included with the ABI can be upgraded to a NEMA 4X or IP-66 rating when the machine will be used in a wash down environment. Special sensors are also available for hard to detect containers such as clear or opaque. Mechanical sensors may be required for low profile or odd shaped containers. A starwheel bottle indexing system is standard but pin indexing is also available. A double pin indexing system upgrade may also be required when filling large containers. The unit is included with 1 bottle indexing starwheel and additional starwheels will be needed for each container shape and size.
• An all-pneumatic upgrade is available for filling flammable products or filling in a hazardous location. The all-pneumatic upgrade includes pneumatic container sensors, pneumatic logic for timer and indexer operation, and container counting. Some available options or upgrades cannot be controlled with an all-pneumatic control package. A more convenient alternative to all pneumatic operation is a remote location control box. This control box uses the normal electronic sensor package and controls located in a box that is attached to the machine by a 25' or 50' umbilical. This allows for the easy to use control package and multiple upgrade options that are used on the normal machine while still allowing the machine to operate in an all-pneumatic configuration. All the sensors used with the PD control package are low voltage. To meet higher guidelines, pneumatic sensors or a fiber optic sensor package may need to be used in place of the low voltage sensors.
• The control package on the Automatic Models include an alpha-numeric Touch Screen display, easy to set up and adjust display menus, total bottle counter, optional diving head mode of operation, and “No Bottle – No Fill” function. All the menus can be adjusted on the fly to maintain throughput while making minor adjustments. The “No Bottle – No Fill” function is a true no bottle no fill step that counts the correct quantity of containers out of the fill area as well as the correct quantity of containers into the fill area prior to starting the next fill cycle.
|Food & Beverages||Cosmetic & Personal Care||Chemical||Pharmaceutical||Other|
|Water||Perfumes||Window Cleaners||Cough Medicine||Insect repellent|
|Fruit Juices||Essential Oils||Laundry Detergent||Urine|
|Vegetable Oil||Nail Polish||Motor Oil||Alcohol|
|Tea||Nail Polish Remover||Ink||Iodine|
|Fruit Extracts||Air Freshener||Stain Removers||Saline Solution|
|Vitamin Drinks||Liquid Soap||Carpet Cleaners||Blood|
|Syrups||Sun Tan Lotion||Paint|
|Tomato Juice||Hair Conditioner||Fuel Additives|
|Salad Dressing||Hand & Body Lotion||Engine Coolant|
|Tooth Paste||Mouth Wash||Wood Stain|
|Peanut Butter||Bubble Bath||Wood Varnish|
|Honey||Hair Styling Gels||Wax|
|Mayonnasie||Facial Mud||Tire Sealants|
|Fruit Toppings||Makeup Remover||Silicone|
|Jellies||Facial Creams||Aircraft Paint|