Can Powder Filler: The Ultimate FAQ Guide
What is Can Powder Filler?
Can powder filler is one of the most crucial packaging machines and is widely used in industries such as cosmetics, food, pharmaceuticals, among others.
Can powder filling machine helps in the operation of filling contents that are pulverized in powder form into containers.
The powder filling machine entails a broad range of free-flowing granulated and powdered products.
It is essential to ensure that the can powder filler does its operations with accuracy and have the capability to manage the powder better.
Can powder filler
How many Types of Can Powder Fillers are there?
There are different types of Can powder fillers to choose.
Let’s look at some of the most common ones you will find in the market.
· Auger Can Powder Filling Machine
Auger can powder fillers are fairly in demand in the filling industry.
The machine is made up a hopper, stirring bar, and an auger within the filling cylinder.
This type of can powder fillers is volumetric, that is, they do not weigh the powder.
However, it may be possible to weigh by fitting the can powder filler with a weighing scale.
Nevertheless, the outcome will rely on the auger’s precise rate of revolutions.
The process of can filling is completely drip-free and precise in weight.
Auger can powder filler has the option of altering the speed of operation, and it provides the operator with the alternative to choose from different range of speed.
Apart from filling of containers, the auger can powder filler also does the accurate measurement.
It has sensors that ensure that the fill volume is according to the wanted mark for various powder products.
· Vacuum can Powder Filler
The vacuum can powder filling machine fills packages, consisting of containers with practically all sorts of powder without utilizing an agitator and auger.
Thus it implies that the powder product does not go through any agglomeration or breakdown.
· Single Head can Powder Filler
A distinct kind of equipment because of its capability to perform all the filling processes through a single filling head.
Moreover, it accurately fills nearly all sorts of powders (non-free flowing and free-flowing) into containers.
In addition, you can find them both semi-automatic and fully automatic types.
· Double Head Powder Filling Machine
Different from single head, this type of can powder filler has two filling heads.
For that matter, it has the ability to handle filling of bulking powder in comparison to single head can powder filling machine.
Double head can powder filler also packages both non-free flowing and free-flowing powders.
· Net Weight Can powder Filling machine
Net weight can powder filling machine is distinct from other types of can powder fillers because it is the only machinery that weighs the powder before filling it into the container.
This helps do away with the need for a check weigher down the production line.
A net weight powder filler transfers products from a hopper through conveyor belts or vibratory trays depending on the product type.
The product flows straight into a bucket fixed onto a load cell.
The feed system reduces speed to “dribble” feed rate as the weight in the bucket approaches the target weight.
In most cases, a second belt or tray is connected that is committed for the dribble feed when you need great accuracy.
After reaching the final weight, the dribble feed gets turned off.
Through a trap door, the net weight can powder filler then dispenses its content into the container.
· Cup Fillers
Also referred to as pocket fillers, this type of can powder fillers is part of the volumetric filling machines.
Cup can powder filling machines are appropriate for packaging free-flowing powders including nuts, coarse granules, and powders.
Cup filling machines are the best option for canning corn, beans, and peas among others.
The powder filling machines are available in both rotary and in-line styles.
· Vertical Form Fill Sealing can powder Filler
The VFFS is special filling equipment compared to other conventional machines.
Though it is one machinery, it executes three functions.
Vertical form fill sealing can powder filling machine develops packaging bags out of a flat film roll of plastic, at the same time also filling the cans with the powder and concurrently sealing the filled cans.
· Injectable Dry Powder Filler
Injectable dry powder filling machine has wide application in the pharmaceutical industries because it has the ability to accomplish fast and accurate operations.
The functioning of this type of can powder filler guarantees negligible wastage of powders.
This can powder filler comes with a rubber stoppering mechanism.
The system enables fitting of rubber caps on the cans after filling them with powders.
The rubber caps are instrumental in preventing the powders from getting adulterated with contaminants.
· Manual Can Powder Fillers
A manual can powder filling machine means your input is required during the entire process of powder filling.
You, therefore, must remain alert and always take part in the process of filling.
For instance, you will perform the gross weighing of the filled cans, establish the exact amount of the fill, stop and restart the filler, among other operations.
· Semi-automatic Can Powder Filler
This types of Can Powder filling machines are in most cases closely linked to fully automatic types, thus the reason why you can upgrade it with little modifications.
Semi-automatic can powder filler may have a single PLC or control, which enables it to execute automatic quantitative filling, changing of measurement errors among other parameters.
Nevertheless, this does not make it automated equipment.
· Full Automatic Powder Filler
This type of Can Powder filling machine employs the most recent technology, making it more accurate, robust and suitable.
The machine executes most of its operations automatically, for example, feeding of materials, measuring and filling among others.
The equipment is fit for filling both granules and powders.
How is Net Weight Filler Different from Auger Can Powder Filler?
Net weight can powder fillers are unique from cup fillers and auger fillers.
Both which are volumetric filling equipment, in that it is the only kind of can powder filler that in fact weighs the product prior to filling into the container.
Powder filling machine
Can Powder Filler is made from which Material?
There are several materials that can be used to make can powder filling machines.
Nonetheless, it is essential to use corrosion or rust-resistant material.
Particularly, stainless steel 304 is the best material for all the parts of the machine, including the powder contact components.
What Powder Characteristics should you Consider when Choosing Can Powder Filler?
It is critical to understand the features of the powder product you would want to package.
By doing this, you will select a suitable can powder filling machine and packaging container.
These important characteristics comprise of:
Double head powder filling machine
· Powder Fineness
The powder of choice may be very fine, fine, modestly coarse, coarse or very coarse.
Make sure you select a can powder filling machine depending on the fineness of the products you will be packaging.
· Powder Flow Properties
These consist of frictional features, flow rate, cohesive strength, angle of repose, permeability, segregation tendency, sliding at impact points, bulk density, among other aspects.
After you have understood all these important aspects, it will be easier for you to select a powder formulation having the right properties.
This information will help you to optimize the process of powder filling with great ease.
What are the Benefits of Can Powder Filler?
A can powder filler can offer various advantages to your production cycle.
Some of the advantages of can powder filling machines comprise of:
· Ensures Products Hygiene and Safety
Manufactured from top quality stainless steel, which aids in maintaining hygiene in the process of production.
Usually, stainless steel 304 is used to fabricate the parts that come into contact with the products.
This is due to the ease of maintaining and sterilizing stainless steel to keep your activity going smoothly without contamination.
· Reduces Cost through Automation
The best can powder filler has alternatives for manual or automatic operation, and is perfect for packaging products in the industrial sector. In addition to filling, can powder filling machines as well have an array of functions consisting of loading, sterilizing, seaming and cleaning.
· Streamline and Improve Production Runs
A can powder filler moves your business to a professional level of manufacturing, enhancing the end product by the effective processing of the line.
For instance, the average can powder filling machine will package over 3000 cans of product every hour and reduce labor requirements.
A machine can as well offer a safer work environment and decrease waste.
Due to these benefits, a can powder filler can add value to your business almost overnight.
· Improves the Products Quality
Buying or adding a can powder filling machine can boost the quality of your products, by minimizing contamination and doing away with the human aspect in the process of production.
There are numerous reasons to one of the can powder fillers to your production line for a higher quality final product.
- Can powder filling machine not only guarantees hygiene and safety of goods, boost product quality, but as well prolong the date of expiry of your products.
Are there Drawbacks of Can Powder Filler?
Absolutely, despite their production efficiency, there are disadvantages of can powder fillers.
Here are some of the few drawbacks:
- Auger powder filling machines are not dependably precise for products having irregular shapes or densities
- Auger can powder fillers can destroy products that cannot sustain compression
- Cup powder fillers cannot dispense non-free flowing products
- Some can powder fillers such as VFFS are relatively costly
- Net weight powder fillers generate too much dust when filling fine powders including talcs, flour, among others.
What are the Main Parts of Can Powder Filler?
Can Powder fillers have several parts and components based on the model and design of the machine.
The most common components of can powder filling machine comprise of:
Parts of can powder filler
- Filling motor – controls the revolutions rate of the filling jar, hence regulating the capacity of the packages.
- Mixing Motor – regulates the blenders’ operation intensity in mixing the powder.
- Mainframe heads – offers exterior shield against any probable mechanical damage.
- Level Detector – a device that establishes the level of powder dispensed into the containers. There are two types; point level detectors and continuous level detectors.
- Feeding Port – provides a channel for the powder products and is made from food type stainless steel 304.
- Hopper – also forms part of the feeding channel, and is made from stainless steel 304.
- Filling spout – another part of the dosing system.
- Worktable – platform for putting the already filled cans.
- Electric scale – for automatically determining the weight of empty or filled packages.
- Overflow collector – trough whose purpose is to momentarily hold the splashed powder products.
- Control box – a locker that houses all the control and power buttons coupled with plugins.
- Pedestal – offers a strong mechanical support structure for firmly positioning the entire machine.
How does Single Head and Double Head Can Powder Fillers Compare?
The double head filler works almost the same to the single head fillers.
The only significant difference comes in the number of filling heads.
Double head powder filler
Single head powder filler
Single head can powder filler is a special type of equipment because of its capability to perform the filling operations through a single head.
On the other hand, as the name suggests, double head powder filler does the operation via two filling heads.
With the double head can powder filling machine, you can fill comparatively bulky products in comparison to the single head powder filler.
In addition, double head powder filler has a higher work rate.
Both types of can powder fillers can accurately fill nearly all powder types (free-flowing and non- free-flowing) into containers.
What Parameters Influence Dimensions of Auger and Tube in Auger Powder Filling Machine?
The auger and the tube dimensions differ when using auger can powder filler depending on the following parameters:
- Rate of dosing
- Level of accuracy
- Container Necks
Always factor in the size of the container that carries the powder products.
In every scenario, the mouth of the container must be in close proximity to the funnel as possible.
For that matter, you should mount the funnel very close to the top of the container.
Doing this ensures that you attain a high degree of precision and a clean fill.
· Weight of the Fill
A small dosing mechanism (auger and funnel) is only able to fill a small quantity of powders at a slow rate; nonetheless with exceptional precision.
Conversely, a bigger dosing mechanism manages bulky powder at a faster rate however variably.
Can powder filler
So which is the best alternative?
A small-sized dosing mechanism is suitable if you intend to package only limited weight of powder products.
Conversely, large-size dosing system is the best option for bulky products.
It is advisable to include a number of sets of tools (dosing mechanism) when handling a variation of fill weight.
This ensures you attain both speed and accuracy.
· Characteristics of the Powder Products
Can powder filler
Powders possess definite and unique physical features, some are free-flowing whereas others are non-free flowing.
Still, some powders may be semi-free flowing.
In the case of free-flowing powders such as granulated sugar or tablet salt, you will need a mechanism of stopping the flow of powder.
The commonly recommended means is the use of a spinner disc.
This method involves mounting a sauce-like disc at the edge of the protruding auger.
Its function is to prevent the powder from flowing.
When dealing with non-free flowing products, you would need a large auger that can swiftly force all the trapped powder down into the funnel.
Moreover, you can control the mode of agitation in a manner such that it speedily break off between the fills to prevent overworking and compaction of the powder.
In situations where the powder gets filled with air as it moves downwards into the hopper, alter the mode of agitation so that it constantly run to force out the air.
In cases whereby the powder is filled with air as it trickles down into the hopper, change the agitation mode so that it continuously run to expel the air.
Generally, a larger hopper assists in homogenizing and de-aerating the powder product by making them go through more agitation, consequently resulting in longer residence time.
In the case of semi-free flowing powder products including such instant coffee powder, which are very delicate may get damaged when the hopper segment has a bigger auger with over-flights.
Therefore, to efficiently handle products of this type, utilize an auger having parallel flights.
Om the other hand,a semi-free flowing powder may rebound even after stopping of the auger.
In such a situation, start off a little back pressure to keep back the products in the funnel by installing a washer below the auger.
What are the Advantages of Vacuum Can Powder Filler?
- Maintains the integrity of products since the breakdown of powder is very minimal.
- Generates minimal or no dust.
- Found in both semi-automatic and fully automatic types.
- Fills both free-flowing and non-free flowing powder products.
- Easy to clean and permits fast changeover of parts
What is the Difference between Inline and Rotary Can Powder Filling Machine Layout?
There exist two main designs for can powder filling machines: Inline and Rotary.
The main difference between the two models is in the machine layout.
An inline can powder filler performs the can powder filling in a straight line, with the starting and ending points of the procedure at opposite sides, calling for more floor space.
A rotary can powder filler, on the other hand, is set up in a circular manner, implying the start point of the filling procedure is right close to the endpoint.
This forms a better ergonomics layout for operators and needs minimal floor space.
How do you Specify Can Powder Filler?
When placing a quotation for a can powder filler machine, here are some of the aspects that you have to focus on and get clarification from your supplier:
Tin with powder
· Control Mechanism
An ideal can powder filling machine is one that is easy and simple to control.
For this reason, choose a powder filler with a digital PLC and a Human machine Interface (HMI).
· Type of Machine
You may choose between a semi-automatic, or a fully automatic can powder filler since these two categories of equipment function efficiently.
In addition, they offer minimal difficulty in operation, you are required to only perform the right inputs.
· Speed of Filling
Make sure you specify a can powder filling machine that has a reasonable rate of production.
Examine your demands and shop for the most appropriate equipment.
· Drive Mechanisms
The motor gives the sufficient force needed by the rotating components.
Make sure you specify the right motor for your can powder filling machine.
There are various types of motor systems available including electric motors, VFD, stepper motor, servo motor and vacuum suction.
Servo system is the most common among the available options.
· Material Type
You have so many alternatives to choose from, but it is essential to ensure that you select a corrosive or rust resistant material.
Specifically, you should go for an all-stainless steel 304 equipment, including the powder contact parts.
· Fill control/Sensors/Detectors/ Timers
A blend of these devices is necessary because they ensure the powder filling process is as accurate as possible.
Detectors facilitate accurate filling, whereas timers monitor the process.
· Filling Error and Accuracy
You should make sure the can powder filler you purchase has a negligible degree of faults in as much as no machine is entirely flawless.
Make it a point to specify a dry powder filling machine with less than 1% filling error.
· Hopper Volume
Always ensure purchase a can powder filler with the appropriate hopper volume that fits the size of your products.
You would require a bigger hopper for bulky products and vice-versa.
· Filling Range
This aspect specifically relies on your filled containers.
So, specify a flexible machine that can manage a broad variety of masses.
Majority of can powder fillers fill up to a minimum of 1 gram.
Can Powder Filler should conform to which Quality Standards?
For you to ensure you purchase a high quality can powder filler, always confirm if they meet this standardization compliance.
- ISO/TC 313 – establishes international standards for both filling and packaging systems.
- cGMP – stipulation that details the minimum requirements for compliance by the manufacturing process intended to guarantee the safety of operators of the machine.
- FDA Compliance – ascertains the compliance of the can powder filling machine with the handling of food and beverage products.
- RoHS – Restriction of Hazardous Substance (ROHS) offers an instruction for the use in case restricted specific hazardous materials existing in electrical and electronic equipment such as can powder fillers.
- CE Mark- specify the compliance of the equipment to health, environment and safety standards.
- CCC Mark- compulsory mark designating manufacturers’ safety compliance for all items sold, imported or used in China.
Take note that these compliance standards differ from one region to another.
Which Industries use Can Powder Fillers?
Can powder fillers have various purposes in different industrial sectors based on the type of use associated with it.
Here are some of the industries that the machine finds extensive use.
Can powder filling line
i. Pharmaceutical Industry
Can powder fillers accurately help in filling of powdered drugs and medications in numerous packages, be it plastic or glass bottles.
ii. Veterinary Industry
Majority of veterinary medicines are produced in powder form, which makes them readily soluble in the drinking water of the animals. Filling of these type of drugs is possible using can powder fillers.
iii. Food and Beverage Sector
Powder filling machines are often used to package fine flour, powdered sugar, milk powder, powdered spices, coffee powders, among others.
iv. Chemical Industry
Both mild and reactive powdered chemicals can be filled using can powder fillers.
v. Cosmetics Industry
The common products in this industry comprise of cosmetic detergents and baby powders.
vi. House Care
Powdered detergents are the most popular products packaged using can powder fillers in this category.
Can powder fillers play an instrumental role in the filling of inorganic and organic fertilizers.
Are there New Technologies in Can Powder Filling Techniques?
Yes,there is an exceptional automation of can powder filler machine.
Manufacturers are incorporating more advanced technologies, such as robotics, to enhance worker safety, increase productivity and lower operating costs.
Work is in progress in developing cobots that enable fast and easy redeployment.
They are equipped with adjustable force and stroke automation tools to integrate varying sizes, shapes, and conditions of raw materials and parts.
Advanced can powder filling machines sensors are also being developed that can direct robotic arms to differently located components on packaging line.
In addition, new tools have been created that can be swiftly programmed and used within a short time, even under the control of inexperienced operators.
SaintyCo offers which Can Powder Filling Machines?
Here you can find so many machine used for filling the cans.
- SAF-1000 Semi-automatic Filling Machine
- PF-200 Double Head Can Powder Filler
- PF-150S Single Head Can Powder Filler
Why Invest in SaintyCo Can Powder Filler?
SaintyCo manufactures and suppliers various kinds of pharmaceutical packaging machines.
These equipment are of the highest quality and standards and guarantee durability and high rates of production.
Our advanced production facility is one of the main reasons SaintyCo can powder filling machines incorporate all the modern technology and devices.
Our can powder fillers boast of exceptional workability and efficiency.
Apart from performing the powder filling, the machines additionally place caps over the container heads to protect the vials or bottles from adulteration.
What are the Benefits of Screw Driven Can Powder Filler?
- More efficient type of can powder filler.
- Fairly dust-free even in the case of fine powders that are blown of easily. This is due to the fact that it works when enclosed even when dispensing the powder products into various packages.
- Can fill both free-flowing and less free-flowing powders though the content has to be consistent during packaging.
- Can be integrated with other packaging machinery such as form and fill machines for bottles and cans.
- Has a wide range of filling capacity thus you do not need to change parts when packaging a different volume.
- Cost-effective machine.
- Has a compact structure making it easily portable.
- Has a PLC that is utilized to operate it via a touch screen. The screen displays in English and other languages, making it easy to use by many people.
How do Can Powder Filler Work?
As we have seen, there are many types of can powder filler which have different working principle.
Therefore, let’s look at how the two most common can powder filling machines work.
· How Auger Can Powder Fillers Work
The filling motor rotates the auger at a constant speed to eject the powder products from the tube.
In the meantime, the mixing motor also rotates the stirring bar which has agitation bar attached in a counter-clockwise direction to that of the auger.
The bar and the blade de-aerate and blend the powder.
Moreover, the agitation blades make sure there is constant filling of the auger flights.
The powder products continuously flow into the funnel through a trap door and eventually fills into a ready can.
· How Net Weight Can Powder Fillers Work
The process begins by the powder products flowing from the hopper via conveyor belts or vibratory trays.
The movement of powder through belts or plates relies on the type of products.
The powder then goes direct into the bucket attached with a load cell.
As the weight of the bucket approaches the set weight, the dosing system slows down to a dribble feed speed.
You may need to add an extra belt or tray particularly for the dribble speed in operations where you require accurate results.
When the target weight reaches, the dribble speed finally stops.
The can powder filling machine, at this point would be ready to dispense its contents via a trap door into the container.
What Powder Filling Techniques are there?
Powder filling industry apply two common powder filling technologies as discussed below:
Tin powder filler
· Volumetric Powder Filling Technology
Volumetric powder filling technique concentrate on the capacity of the fill.
This implies the number of rotations of the auger, for instance, is directly proportional to the amount of fill in a can.
This concept involve either single or multiple augers, regardless whether you are employing a semi- or fully automatic can powder filler.
You may connect a volumetric powder filling machine to a weigh cell to optimize its operation.
This is crucial because the weigh cell:
- Eliminates (minimal/excessive) weights
- Efficiently registers and displays the fill weight.
- Makes up for any trend changes in the fill density.
With the kind of information determined by the weigh cell, the PLC automatically transmits it back to the filling head.
In turn, it starts appropriate action either by decreasing or increasing the rate of rotation of the auger.
Nevertheless, even when you use a semi or fully automatic can powder fillers, you may still get some negligible degree of error.
It is insignificant when filling light weight products such as oral dry suspensions into containers.
However, if you need completely no error in weights, then you will have to perform some modifications.
Add tare and gross weighing gadgets to the volumetric powder filler so that you would utilize two weigh cells.
The tare weighing device determines the weight of unfiled bottle, while the gross weighing device establishes the weight of full bottle.
Eventually, when working out the net weight, you minus the tare weight from the gross weight.
· Gravimetric powder Filling Technology
A fill-by-weight filling can powder filler may be your best choice because of a number of factors:
- Tare weight inconsistency
- criticality of the fill weight,
- Inconsistencies in product density
- Give-away in cost of product
- Need to verify the real fill weight filled.
Powder filling machines comprising load cells or balances can be found in several configurations, though they all apply three main means of regulating the fill weight:
· Setpoint (dynamic weighing)
In this mode, the auger operates at a single speed and the live fill weight determined by the load cell.
The system will stop filling after reaching the pre-set setpoint weight.
The resultant weight will be a sum of the setpoint weight and any inflight material.
· Bulk and Dribble (dynamic weighing)
Here, the auger works at a high speed for most of the fill (bulk) and then reduces speed to a dribble speed for the rest of the filling.
The load cell keep track of the live fill weight and gives alert for the dribble fill to pause.
· Bulk and Feed Forward (static weighing)
In this case, the auger operates at a high speed for the better part of the fill (bulk) but gets stopped just before reaching the set fill weight.
The load cell measures a static weight and the needed top-up fill is worked out and changed into a volumetric fill.
Even though the top-up fill volumetric, you can attain a general accuracy of ±0.2%.
The commonly applied configurations include:
· Single Head, Gravimetric
In this type of configuration, you can use a single weigh-cell located directly below the filling head exactly in the same manner as when powder filling semi-automatically: “bulk and dribble’, “bulk, predict and top-up”, and “single shot”.
With the help of the weigh-cell, you can tare weigh the unfilled container and acquire data as needed.
· Dual Head, Volumetric Bulk Fill with a Gravimetric Top-up
Alternatively, you could use two filling heads, but rather than the two heads dispensing onto two live weigh-cells to double the production, you could use a bulk and top-up system.
This is beneficial because it gives the optimum of speed and accuracy.
The volumetric first head with a large auger, quickly bulk fills, and the second head having a more precise smaller auger performs the gravimetric top-up fill.
· Dual Head, Bulk and Predict
For even higher speed and accuracy, you can move the weigh-cell between the two filling heads.
Converting it into a bulk fill, predict forward and top-up device with instant weighing.
In this configuration, the weigh-cell would communicate back to the bulk filling head to sustain the quantity of the bulk fill, communicate forward to the top-up head, and estimate the required top-up dose.
All these three operations take place simultaneously.