TFC-60D Monoblock Liquid Filler

Monoblock Filling Machine: The Ultimate FAQ Guide

In this guide, you will find all information you are looking for about monoblock filling machine.

Whether you want to learn about features, components, features and benefits, just to mention a few.

So if you want to learn more about monoblock filling machine, read this guide.

What Is A Monoblock Filing Machine?

This is a system of machines that comprises of a variety of packaging equipment placed on a single chassis.

It mostly comprises of a filling machine working together with a sealing, a cleaning or a capping system though not mandatory.

A star wheel is used to move the containers from one packaging system to the next by rotating in a consistent speed.

monoblock filling machine

 A Monoblock Filling Machine greatly reduces the space needed for the packaging equipment compared to conventional inline systems.

The starwheel replaces the complicated and long conveyer system that transfers the containers to be filled.

Other standalone machines used in packaging are interchanged by mechanisms serving the same purpose around the starwheel.

What Are The Different Types Of Filling Machines?

Monoblock Filling Machines can also be called flow filling machines and are mostly applied in the beverage industry besides other industries.

A precise quantity of liquid-based product is dispensed based on the programmed container sizes.

This Machine can also be programmed to fill other products like cooking oil, salad dressings and alcoholic beverages.

The common Monoblock Filling Machines are:

Manual Monoblock Filling Machine

This kind of filling machine does not need electricity and functions using manual operation.

Accuracy is improved with an increase in the output speed as opposed to pouring by hand.

They are recommended for production in small scale and also in laboratories.

monoblock filling machine

Semi-Automatic Monoblock Filling Machine

Its mode of operations uses a nozzle together with a piston and syringe to achieve a zero-drip process.

This kind of Monoblock Filling Machine works well with very my forms of liquids like pharmaceutical and cleaning merchandises.

semi automatic monoblocking machine

Fully-Automatic Monoblock Filling Machine

This Filling Machine is able to operate in large scale operations that require high levels of production.

It is mostly preferred in large industries and used in food products and liquids with high viscosity.

automatic monoblock filling machine

Inline Liquid Filing Machine

Its operation involves pouring both high and low viscous fluids to containers in a conveyor belt.

It is mostly used in cosmetics and dairy food products.

inline liquid filling machine

Rotary Liquid Filling Machine

Containers are moved from one circular station to another with each station having a designated purpose.

The functions performed in each rotary station include filling, capping and sealing.

Mostly applied in the automotive industry as well as the food and beverage industry. Personal care products are also filled using this machine.

Rotary liquid filling machine

Piston Filling Machine

Products are poured into containers using high levels of precision in the above Filling Machine.

It is majorly used to fill liquids that possess a restricted changeover like food sauces, liquid soaps and cosmetics.

Piston filling machine

What Are The Benefits Of Customizing Monoblock Filling Machine?

For the monoblock Filling Machine to be very effective, its customization should be directly linked to its automation.

The highest level of accuracy of the machine can be achieved when it is well tailored to the clients’ operation requirements.

Customization includes such parameters as the volume of liquid required, the properties of the liquid and the equipment footprint.

customized monoblock filling machine

 The shape, weight and the size of the vessel are also part of the machine customization.

An increase in the machine accuracy and its efficiency means errors are reduced and output is greatly increased.

This will ensure an equitable Return on Investment on the machine.

What Are The Components Of A Monoblock Liquid Filling Machine?

The Monoblock Liquid Filling Machine contains a set of components that include:

• A stand for feeding the containers that has an adjustable height and made f stainless steel.
• An air blow conveyer for bottle in-feed.
• An automatic rinsing, filling and capping machines in one Monoblock Liquid Filling Machine
• A cap elevator unit that is automated together with a cap feeder.
• An output conveyor that is made of stainless steel.
• A light station that is online for inspecting containers.
• A table for inserting security seals and sleeve made of stainless steel.
• A machine for shrinking labels that can either be steam or electric
• Spare bottle changing parts for different bottle sizes and liquid volumes.
• An option of label or sleeve inserting machine (depending on client’s customization)
• An inkjet printer for printing dates (optional component).

How Does A Monoblock Filling Machine Operate?

The Slat conveyor, which is stainless steel receives dry containers that are incoming and have been manually fed by hand.

The containers then move forward at a well-regulated speed towards beneath the filling unit.

The filling unit is composed of nozzles used in filling, syringes made of stainless steel and a filling head.

A bottle stopper is also included in the set up and holds the container while the filling is ongoing.

The syringes are attached strategically on the eccentric block and they drive through the main gear box located at the bottom.

Adjusting the piston stroke length leads to either an increase or decrease in the volume filled.

To avoid a variation in the volume, the syringes have a non-return valve used for sucking and delivering liquids.

Transparent silicon pipes are used to deliver the liquid to the filling nozzles.

The nozzles use a cam mechanism for upward and downward movement.

When the star wheel holds the container, the nozzles move and then up when it starts filling the container.

The containers then move on a turntable after the filling process where caps are put on every individual container.

They are then taken to the sealing station where a rotating sealing head carries out the sealing operation.

Completely filled and sealed containers are then collected on at an outfeed table for packaging and eventual shipment.

What Is A Monoblock Positive Displacement Pump Filling Machine?

This type of filling machine operates under the design principle of a positive displacement pump head to fill liquids.

It is mostly used in filling liquids with high viscosity such as lotions, creams and gels.

What Are The Features Of A Monoblock Filling Machine?

Features common in most of the Monoblock Filling Machines include:

• The Monoblock Filling Machine is custom designed according to the buyer’s preferences and manufacturing requirements.
  The structure is usually made out of stainless steel metal.
• It contains a smart touch screen that is used as the Human Machine Interface (HMI). The design is very simple to operate as it has been humanized.
• Its positioning design is very tight and can easily be manipulated. This makes is ideal for filling a variety of containers with different sizes.
• It contains a valve that performs high-speed filling thus eliminating leakages and dripping. They also ensure a very precise filling volume is achieved.
• They contain a highly efficient Pneumatic Execution Control Valve which guarantees safety during operations.
• The sensors used are photoelectric with a link control that is pneumatic. This ensures that a shortage of bottles is automatically prevented.
• They use a Programmable Logic Controller (PLC) that makes it easy to have parameters modified and container sizes altered with.
• All the Pneumatic components are highly reliable and extremely stable during operation.
• Their Fill Accuracy is very high and assisted with an automated No-Bottle No-fill type of operation.

What Are The Factors To Consider When Choosing A Monoblock Filling Machine?

There are various factors that need to be taken into consideration when choosing the most appropriate Monoblock Filling Machine.

Such factors include pistons, gravity and liquid overflow together with pumps and your end goal.

Answers to the following questions can help a great deal in guiding towards settling for the most suitable Monoblock Filling Machine:

What Product Is Being Filled?

The product being bottled is the first thing to factor in when choosing a filling machine.

Various Monoblock Filling machines have different capacities to handle different liquid viscosities.

A liquid that is highly viscous can well be handled by a piston filler better than an overflow filling machine.

Less viscous liquids are better filled with a gravity filler compared to a piston filling machine.

The viscosity levels for various types of machines tend to overlay but filling some liquids eliminates certain types of fillers from production.

Does The Product Possess Distinctive Features?

The choice of Monoblock Liquid Filler is influenced greatly by the unique characteristics of a product.

Some products may experience changes in their viscosity due to surrounding temperature changes.

Some liquids may also contain particles such as liquid soaps or have vegetable chunks such as spaghetti sauce.

Filling such liquids using either gravity filler or an overflow filler may lead to blockage or jamming of hoses or nozzles.

This will result in a very inefficient process of filling.

A piston filling machine will be the most suitable for filling such because it can allow the chunks through its pathway.

What Kind Of Bottle Will Be Used?

Taking into consideration the type of container or bottle to be used helps in arriving at the ideal choice of a Monoblock Filling Machine.

A clear glass bottle or container can best be filled with a level filler which ensures filling to equal levels visibly.

Some products may also have small or large containers that eventually determine the nozzle or machine for filling.

The package used also determines the liquid filling machine well suited for the project.

How Does Monoblock Liquid-Level Filling Machine Compare To A Volumetric Filling Machine?

Volumetric Filling Machines fill the containers with an exact liquid product volume. It does not consider the visual appearance of the eventual fill level.

The Monoblock Liquid-level Filling Machine fills bottles up to a certain level on the bottle.

monoblock liquid level filling machine

 Even though the exact volumes in each bottle may not be the same, the liquid level in them is filled the same.

This is because some containers or bottles may contain slight and naturally occurring disparities in their volume.

This happens even when they visually appear similar in size and shape.

volumetric filling machine

What Are The Pros And Cons Of A Monoblock Filling Machine?

Before setting up a Monoblock Filling Machine, its pros and cons have to be critically looked at.

The Pros

Better Container Control

A typical Monoblock Filling Machine, filling and capping are two different systems.

Being separate, a control system is required to synchronize the capper to filler speed.

They include sensors and other complex systems that regulate the capper speed to sustain a constant backlog.

This enhances the container movement and makes filling very efficient and time-saving.

Saves Floor space

If all the component machines in a Monoblock Filling Machine were stand alone, they would occupy a significantly larger amount of space.

This will have to include the connecting conveyors between each individual component machine.

Additional floor space tends to be expensive and will reflect on the product cost.

Monoblock Filling Machines safeguard this prized resource.

Flexible Filling Capacity

Monoblock Filling Machines are usually recommended for filling bulk liquid products sold in bulk.

The machines are extremely flexible because accurate computer systems can be programed to fill any size of container.

Semi-Automatic and Automatic Features

Modern Monoblock Filling machines are either semi-automatic or automatic thus reducing the labor cost on employees.

The liquid is contained in a holding tank on top of the machine and computer-control valves fill the containers from there.

Limitations Of Monoblock Filling Machine

Flexibility Redesign

Individually, fillers, labelers and cappers can be repurposed for operations in other industries or lines.

The entire Monoblock Filling Machine is however specifically designed for a series of operations.

It may prove impossible to reconfigure the machine for a product that needs a screw cap instead of a crimped cap.

If marketing changes a round bottle to rectangular, the Monoblock Filling Machine will no longer work.

Maintainability

The more the functions get placed in a single smaller space, the more complex the Monoblock Filling Machine becomes.

This makes it hard for the machine to be worked on during maintenance, servicing or a breakdown.

If any individual component machine of the Monoblock system breaks down, then the entire machine is dead.

How Does A  Monoblock Liquid Filling Machine Compare To Agitator/Auger Filling Machine?

While a Monoblock Liquid Filling Machine deals exclusively with filling liquids, the Agitator Fillers are designed for Dry Mixes filling such as flour.

The mix is contained in the cone-shaped hopper which then feeds it into a pouch.

Augur filling machine

The mechanism uses an auger conveyor solely under control of the agitator. Pouches and polythene papers are filled and sealed using heaters.

How Does The Monoblock Liquid Filler Compare To A Capsule Filling Machine?

While a Monoblock Liquid Filling Machine deals exclusively with filling liquids, the Capsule Filling Machine does filling relying on pieces and numbers.

capsule filling machine

They have the ability of counting precisely gelatin capsules that are either hard or soft, pills and tablets.

What Are The Different Heads Used In A Monoblock Liquid Filling Machine?

Some of the most common heads include:

Washing Heads

They clean bottles by applying a high nozzle spray and prevent the threaded parts from getting into the bottle.

Filling Heads

They fill the bottles by using gravity at high speed and with great precision.

They have filling valves and operate having the rack drive system move them through gear transmission.

Capping Heads

They operate automatically under the principle of ‘no bottle, no capping’.

They are made of stainless steel and stop working when there are no bottles in line.

What Are Common Problems Of A Monoblock Liquid Filling Machine?

Just like all other machines, the Monoblock Liquid Filler is also susceptible to the regular potential breakdowns with wear and tear.

Such mechanical malfunctions should regularly be addressed before the interfere with the production process.

Such problems include:

Foaming And Dripping

Such problems in a Monoblock Filling Machine are most likely caused by having inadequate seals.

The dripping and Foaming leads to liquid losses and increases the product cost over time.

This problem is solved by ensuring all seals are tight and that no valve is leaking during and after the filling process.

A totally damaged seal may require a total replacement of the entire filling machine.

A diving nozzle can also be used to eliminate such problems.

This is because the nozzle reaches the containers bottom when filling therefore preventing foaming.

Erroneous Timing And Filling Levels

Another product-wasting problem that can interfere with the filling process is the error in the filling and timing.

Incorrect filling levels may lead to liquid overflows or insufficiently filled containers leading to surpluses.

Faulty seals are a common cause of inaccurate filling process.

Wear and tear on the seals should be investigated and either replacing them or tightening them.

Other causes are low or high pressure on the air hoses and spacers on the Monoblock Filling Machine.

Inaccurate adjustments of timing on machines with touchscreen displays is also a cause and adjustment on the screen solves the problem.

Power Problems

Unlike all other Monoblock Filling Machine problems, inadequate power mostly has to do with the facility rather than the equipment itself.

Power surges need to be avoided by taking necessary steps while having enough supply to efficiently run the machine.

It is advisable to have a power generator in the facility with enough power to handle any new equipment in the machine.

This will avoid expensive breakdowns and ensure the machine operates efficiently.

How Does The Monoblock Filling Machine Compare To Vibratory Weigh Filling Machine?

While a Monoblock Liquid Filling Machine deals exclusively with filling liquids, the Vibratory Weigh Filling Machines have a bucket for filling.

It contains numerous vibrating trays that allot the product into the weigh bucket.

vibratroy weigh filling machine

When the necessary weight is achieved, the bucket automatically dispenses the product onto a container underneath it.

They are mostly used in filling granular products requiring specific weighing.

How Does A 3 In 1 Rinsing-Filling-Capping Monoblock Machine work?

The comprehensive machine operation process is as follows:

• TThe air blower conveyor captures the empty bottles which takes them to the rinsing unit via starwheel and worm screw feeder.
• The grip neck holders turn the bottles upside down at the rinsing station and pure water under pressure sprayed inside them.
  The water drain while the bottles move after rinsing and turned upright.
• The star wheel then forwards all the clean bottles to the filling station.
• The liquid is then filled in the bottle using micro-gravity filling nozzles with precision and speed. No filling occurs if there is no bottle in-line.
• The star wheel then forwards the bottles to the capping station where capping is automatically done.
• The bottles will come out of the Monoblock machine after capping to an out-feed conveyor. For visual quality inspection, they pass before a light inspection station.
• The label inserting table at the outfeed conveyor is where neck security seals and bottle labels are manually placed by people.
• A shrink tunnel along the conveyor is where these labels and seals will go through shrinking and ready for packaging.

What Are The Technical Specifications Applied In The Monoblock Liquid Filling Machine?

The technical specifications required when ordering for a Monoblock Filling Machine are:

• The Production output
• Number of Filling Heads
• Number of Capping Heads
• Diameter of the bottle
• The Capping type
• The cap size
• Filling Range
• Syringe Fill Range
• Accuracy
• Electrical supply
• Power (horse power)
• Conveyor Height
• Overall Dimension

You Can Also Consider:

Syrup Filling Machine

Powder Auger Filler

Oral Syrup Filling Line

Tube Fillers

For all your monoblock filling machines, contact SaintyCo now.