When should you buy an overflow filler:
Over flow filling has been used has been used to fill low viscosity liquids for many decades, if it’s used for the right product and a correct set up it will give you a very accurate fill
The overflow filler will give you the fill level by the depth off the return tube inside the container, once the product reaches these tube It will go through the tube instead of continuing to fill your container. If you reach the overflow tube in four seconds and leave it filling for more time the fill level in theory will be the same, keeping this in mind when you set-up an overflow machine will help you understand that you only need to fill for enough time so all the nozzles have overflown. All fill nozzles will not fill at the exact same rate and it won’t matter, if you leave the machine filling for enough time eventually all containers will fill and you will get an even cosmetic fill.
We talk about a cosmetic fill because the machine will not know what volume it is filling it will only do it by height so if the bottles you purchase have an internal volume that it’s different the machine will always feel the same height but the larger bottle will have more product than the smaller bottle by volume.
There are many settings but you can have an overflow filler some machines Have the capability of filling at different speeds at different times, this is very useful specially on larger containers because you will be able to fill at very high speeds at the beginning and slow down at the end to avoid splashing, if you don’t have this option you will have to fill all the container at the highest speed on which the machine will not splash.
Most nozzle designs on overflow liquid filler will drip, not because they are defective but because the get wet and when they come out there is product on the outer tube, so when the nozzles come up and they drip while the containers are moving you will get product on the outside of your bottles. An easy solution for this is a drip-tray that most companies offer.
By far, the biggest limitation of an overflow liquid filler is not being able to fill thick products, or high viscosity products. Different companies offer different solutions and some companies like to take on projects of higher viscosity than other. If you plan to fill a product thicker than water, make sure you get written guarantees.
The main problem with filling high viscosity products is that the product will have to overflow, so if it’s to thick instead of overflowing it creates an internal pressure inside the container that is stronger than the top seal and instead of overflowing the product comes up and spills from the top of the containers, trust me, not fun!!!
There are different nozzle designs that can help for thicker products, larger overflow, assisted overflow with vacuum, suck-back, etc.. Make sure the nozzle will work for your product and container.
After all’s been said, overflow fillers are a great solution for thin low viscosity products and can be pushed to work some thicker products
Will an in-line bottle capper work well with large diameter caps?
The main issue or most common problem that you will have with working with large diameter caps is cross threading, It is very common and in some cases it simply can’t be done on in line cappers.
To be able to address this question we have to take into consideration that every bottle and every cap behave differently, and there are bottles and caps that have been designed so an inline bottle capper will work well with them. On the other hand there are bottles and caps poorly manufactured or poorly designed that will have difficulties in any type of bottle capper.
Having said that if your bottle has a good design it will be a lot easier to set up your bottle capping machine to work properly, But keep in mind that the larger caps are harder to set up than smaller caps, And the required applying torque is much higher.
Here are some features that an inline bottle capper should have to handle larger diameter caps:
1) Spring loaded capping discs, If the machine has this feature in addition to being able to torque much higher you will be able to get more contact on your cap because your capping disc won’t necessarily have to be tangent but can actually be half an inch or more into the cap and follow the contour of it.
2) Reverse first set of spindles, This feature has become very popular and with the right bottle and will work great but if your bottle and cap are not designed to use this feature it won’t do any good. The reverse spindles will work when your bottle has a non-threaded space so when the bottle picks up the cap, then the spindles reverse or unscrew the cap it will use that space and sit flat before going into the next spindles where it will be torqued.
3) Inspection and bottle reject, It doesn’t matter how well your machine is set, you are going to get a few misses, a great set up will give you more than 99.5% correct capping placement (that is 5 Incorrect Bottles out of every thousand) but that number will be a lot lower on large diameter caps, so if you’re getting a 98% correct placement that means you’re getting one bad bottle out of every 50 and If you’re running at 50 bottles per minute you’re getting between 1 and 2 bad bottles every minute, so you will probably have someone dedicated to checking the the caps. If you install a bottle reject this unit will take out all the bad bottles, and place those in a reject table, so instead of having a dedicated person supervising your machine you can have the Line supervisor just check every 10, 20 or 30 minutes the bottles sitting on the table. And fix that issue in a couple of minutes instead of having a dedicated person for that task.
The conclusion would be that each application is different so before you decide which manufacturer you will be buying the bottle capper from, make sure they give you a performance guarantee and see if that matches your expectations and/or necesities
ACASI Machinery began it’s business as a used equipment dealer and equipment remanufacturing, troubleshooting, parts, etc.. selling exclusively in Venezuela.
After 8 years in the used equipment business, realizing that good service, part replacement for such a wide variety of used machines in the market would be impossible to achieve, the company started manufacturing it’s own equipment in a basic machine tool shop.
Since then we have invested heavily on our machine shop and now own one the best machine shops in the world for this type industry. Our capabilities include:
4 CNC Vertical machining centers (Different size tables)
4 CNC Lathes
2 CNC mills
The company based it’s first machines on equipment that already had been in business for many years, and certainly learned from the experience.
The first machine the company sold was a semiautomatic piston filler in 1998 since then it has developed, automatic inline piston fillers, overflow fillers, pump fillers, gravity fillers, automatic and semiautomatic cappers with a wide variety of cap feeding mechanisms, bottle feeders and bottle unscramblers.
In 2003 Acasi Machinery inagurated is sales office in Miami FL were the machines are assembled with all US “Off the shelf components”.
ACASI Machinery was founded with the main purpose of delivering excelent quality machines at reasonable prices, something the packaging machinery business has been missing for years.
We can offer quality designed machines through our extensive experience in the remanufacturing of bottling and packaging equipment.
All parts are manufactured in our machine shop with cnc milling, turning, shearing and bending equipment as well as first class welding and polishing.