Filling Machines and Dosing Machines

Filling machines or dosing machines are essential pieces of equipment used in food processing and packaging. They measure a dose of processed food product by various means, and feed the product into be enclosed in bags, pouches, cartons, cans, jars, bottles and other types of packaging.

What are the types of food filling machine?

Filling machinery comes in portable tabletop designs or floor standing configurations which can be integrated into food processing and packaging lines, including form, fill seal lines.

Compact, single nozzle machines are used in small, low cost food processing lines. They are suitable for many different foods, including soups, sauces, salad dressings, ready meals, coleslaw, yoghurt, hummus, peanut butter and jam.

Multi-nozzle machines significantly increase throughput capacity by simultaneously filling multiple containers through an increased number of filling heads. Filling heads can be arranged on a rotor (rotary filling) or in a line (linear filling).

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How do food filling machines work?

Most food filling machines operate with product fed into a hopper then pumped pneumatically or by vacuum, or fed by an auger screw. The product is passed through a nozzle or filler head, with portions measured by volume or weight, into containers and packaging of various types. For some products, the material is fed onto another component of the food product such as bread slices for sandwiches or pie cases.

Manual filling machines are often operated by a hand lever used to pump product through the feeder nozzle. This type of equipment is most suitable for small production facilities, and for locations where electric supply or compressed air is not available for pumping the product. Manual filling machines are more accurate and less prone to spillage than pouring or portioning the product by hand.

Semi-automatic filling machines are usually operated by pumps driven by compressed air. Filling can be set to repeat, and the machinery will offer greater speed and accuracy than manual filling machines. Precise portions can be filled through accurate measuring and dosing equipment incorporated in the weighing or volumetric controls.

Automatic food filling machines feature controls and inline equipment which manages the filling process from material handling, loading, dosing and packaging. The equipment is often scalable with the ability to increase the number of filling heads. Automatic filling solutions offer larger scale operations high throughput and optimum efficiency.

As with all food processing machinery, hygiene is critical, and ease of disassembly for cleaning is an important design consideration.

Types of food handled by food filling machines

A wide range of food filling machines are available and are designed to handle a comprehensive range of food products. Equipment can be set up to handle individual food filling requirements.

The following products are frequently handled by food filling machines:

Salads
Peanut butter
Jams and preserves
Pizza toppings
Sandwich fillings
Ready meal preparations
Coleslaw
Pasta salads
Yoghurts
Cream
Hummus
Sauces and marinades
Raw meat
Meat mixes and pie fillings
Meat sauces
Corned beef
Luncheon meat
Grated cheese
Pates
Pasta
Rice
Fish paste
Fish fillets in sauce
Fish in oil
Fish roe
Oils
Vinegar

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Flexible Package Filling Machines

Bag Filling and Sealing Machine

Packaging machine in which pre-made bags are taken from a magazine, opened, filled using any of the filling mechanisms described in sub pages one, two, or three, and then sealed in the machine using a variety of methods but typically heat or adhesive. Bag fill and seal machines are used to pack flour, dog food, seeds, ground coffee and chemicals.

Stand-UP Pouch Filling and Sealing Machine

Packaging machine in which pre-made stand up pouches are taken from a magazine, opened, filled and then sealed in the machine using a variety of methods but typically heat or adhesive. Stand-up pouch fill and seal machines are used to pack cat food, sauces and olives.

Reel Fed Bag Filling and Sealing Machine

Packaging machine which separates pre-made bags from a reel before being opened, filled by hand or using any of the filling mechanisms described in sub pages one, two, or three, and sealed in the machine.

Sack Filling and Sealing Machine

Packaging machine in which pre-made sacks typically made from paper or plastic are taken from a magazine opened, filled generally using a nett weigh filling machine and sealed in the machine using heat seal or a stitching attachment or a combination of these methods.

Blister Filling and Sealing Machine

Packaging machine that takes a pre-formed plastic blister from a magazine which is filled and then sealed to a backing card or film to secure the product inside the blister. Blister filling and sealing machines are used to pack tools, tooth brushes small toys and DIY products and produce a package which is similar to that produced on a thermoform fill and sill machine but should not be confused with a blister form fill and seal machine which is used to pack pills.

Liquid Bag-in-Box Filling and Sealing Machine

Packaging machine in which a pre-made bag is filled with liquid using one of the filling methods described in sub pages one, two or three and sealed before being placed into a carton which is then closed.

Valve Sack Filling Machine

A packaging machine in which pre-made paper valve sacks are taken from a magazine opened, filled typically using a nett weigh filling machine and sealed in the machine. Valve sack filling machines are used to pack cement powder.

Gravimetric Filling Machines

Nett Weighing Machine

Filling mechanism which measures out a predetermined mass of product, usually free flowing solids, before dispensing it as a fill. These machines can weigh products as diverse as sand, vegetables and breakfast cereals. Fillers of this type are suitable for weighing products at both low and medium speeds.

Selective Combination Weighing Machine

Also known as a Multi-Head Weighing machine, this is a nett weighing machine with multiple weighing units that computes an appropriate combination of loads to achieve a predetermined mass, before discharging them together as a fill. (See also Form Fill Seal and Inspection & Weighing Pages). Weighers of this type are suitable for accurate filling of products like potato crisps or salads at both medium and high speeds.

Gross Weighing Machine

A filling machine sometimes known as a weigh filler which measures out a predetermined mass of product, which may be liquid, powder, gas or solids, directly into the package which is resting on a weighing instrument which controls the filling operation. This method of weighing is used for products as diverse as jars of instant coffee, litre bottles of oil and 200 litre drums of chemicals. Gross weighing machine are suitable for accurate filling of products at both low and medium speeds.

Count Filling Machine

Packaging machine used to measure solids according to a predetermined count. A machine used commonly to pack pills into small rigid containers, or in hardware packing for small DIY items such as screws and nuts.

Level Filling Machines

Vacuum Filler

Filling mechanism that fills a product, usually liquid or powder, to a predetermined level in a rigid container; the flow is initiated by applying a vacuum to the container. This technique is used for filling liquids like wine and free-flowing powders like milk powder. Vacuum fillers are suitable for accurate filling of products at both low and medium speeds.

Gravity Filler

Filling mechanism used to fill a product, usually liquid to a predetermined level in a container, the product flowing under gravity. This is the classic method of filling non-carbonated drinks into glass bottles. Fillers of this type are suitable for accurate filling of products at low, medium and high speeds.

Pressure Filler

Filling mechanism used to fill carbonated liquid products under gravity to a predetermined level in a rigid container, with the product under pressure. Fillers of this type are suitable for accurate filling of products at both medium and high speeds.

Rigid Container Filling Machines

Ampoule/Vial Filler and Closer

Packaging machine in which glass ampoules or vials are first filled with liquid then fitted with a closure or fusion sealed with a flame. Typically the filling methods used are volumetric piston, level, weigh filling or timed flow.

Bottle Filling and Capping Machine

Packaging machine in which bottles are first filled with liquid and then fitted with a cap, cork, crown cork, roll-on pilfer-proof closure (ROPP), or other type of closure. Typically the filling methods used are volumetric piston, level, weigh filling or timed flow. Machines will usually be rotary with one carousel for filling and a second carousel for capping the bottles.

Can Filling and Seaming Machine

Packaging machine in which cans are first filled with product, which may be liquid or solids in suspension (e.g. baked beans) and then closed by seaming an end piece or lid onto the can. Typically the filling methods used are volumetric piston, level, or weigh filling. Machines will usually be rotary with one carousel for filling the cans and a second carousel for seaming the cans.

Cask/Keg Filler and Sealer

Packaging machine in which casks or kegs are first filled and then sealed usually with a plug or crimped cap. Typically the filling method is gross weight filling.

Cup/Tub Filling and Sealing Machine

Packaging machine in which pre-made plastic cups or tubs are taken from a magazine or stack, filled and then sealed using a heat sealed aluminium or plastic membrane or with a press on lid, or both. Cups are typically indexed from the filling station to the closing station either using an intermittent motion carousel or an in-line transport mechanism. Cup filling machines are used to pack products like yoghurt, cream or margarine.

Tube Filling and Sealing Machine

Packaging machine that takes a pre-made collapsible tube made from metal or plastic, from a magazine which is filled typically using a volumetric piston filler and then closed by folding, crimping or heat sealing, depending on the material used to make the tube.

Volumetric Filling Machines

Volumetric Piston Filler

Filling mechanism which measures out a product, usually liquid, gas or paste, using a reciprocating piston of predetermined volume. Fillers of this type are suitable for accurate filling of products at both low and medium speeds. Volumetric piston fillers are used to fill products as diverse ice cream, shampoo, jam and even mashed potato onto a ready meal.

Displacement Filler

Filling mechanism which measures out a product by displacing a predetermined volume of product with a loose fitting piston. Displacement fillers are slightly less accurate than piston fillers but are used in situations where it is important not to damage the solids in the product.

Aerosol Gassing Machine

A volumetric piston filling machine designed specifically to fill propellant gas into an aerosol can or canister. Fillers of this type are suitable for accurate filling at both low and medium speeds.

Rotating Chamber Filling Machine

Filling mechanism which measures a product, usually liquid gas or paste, using a metering pump that operates for a predetermined number of cycles. Fillers of this type are used in situations where a single machine is required to fill a wide range of product volumes. Rotating chamber fillers are generally used for low speed applications.

Flow Meter Filler

Filling mechanism which measures out a product, usually liquid, using a flow meter. If based on an inductive flow-meter these machines are restricted to use with water based liquids but have the benefit that they are easy to clean and are tolerant to included solids. Flow-meters based on the Coriolis principle can also fill non-aqueous products like oils. Fillers of this type are suitable for accurate filling of products at both medium and high speeds.

Auger Filler

Filling mechanism which measures out a product, usually powder or free flowing solids, using an auger which is rotated for a predetermined number of revolutions in a conical hopper to discharge the required volume of product. The main benefit of these machines is their ability to control dust during the filling operation and are therefore used extensively for powders and dusty free flowing solids. To compensate for changes in the bulk density of the product, auger filler are frequently used in conjunction with a weighing instrument like a checkweigher. Fillers of this type are suitable for filling products at both low and medium speeds.

Volumetric Cup Filling Machine

A filling machine which measures out a product, usually free-flowing solids or powder, in a cup of predetermined volume. These machines are typically used for products like rice or frozen peas which do not generate dust. Fillers of this type are suitable for accurate filling of products at both low and medium speeds.

Timed Flow Filler

Filling mechanism that measures a product, usually liquid or powder, by controlling the product flow duration to a predetermined value. This indirect method of achieving a volumetric fill has the benefit of being relatively low cost and easy to clean. Fillers of this type are used in situations where a single machine is required to fill a wide range of product volumes. Timed flow fillers are generally used for low speeds.