Finding the Best Automatic Liquid Filling Machines for Your Needs

At ZimaPack, we understand that the decision to switch to an automatic liquid filling machine can be venturing into the unknown, which is why we are proud to offer a unique, consultation-based approach to every manufacturer’s needs and unique filling process.

Every liquid manufacturer has unique needs based on the type of liquid, the bottle materials, and production scale. Our approach is to first understand your specific requirements.

Whether you’re handling viscous liquids or delicate beverages, our machines offer unparalleled precision and efficiency, maximizing the amount that you get done all in a single machine. ZimaPack offers solutions that can handle a diverse range of bottle materials, including glass, plastic, and aluminum, setting us apart from conventional options for automatic liquid filling machines. We are committed to delivering high-quality, cost-effective solutions that truly elevate your production process.

Special Features & Applications:

  • • Hotfill (heated/jacketed tanks and nozzles & temperature probes with alarm settings)
  • • Automatic Tank Mixers for liquids with Pulp/Particulates
  • • Pressure Systems/Tank-less Fillers for viscous products
  • • Nitrogen Blanket Tanks & Nozzles
  • • Explosion Proof
  • • Wash-down Environment Upgrades
  • • Pharmaceutical Environment Upgrades
Type of Products Our Machines Can Fill
CLICK HERE TO LEARN MORE ABOUT THE TYPES OF PRODUCTS AND CONTAINERS OUR MACHINES CAN ACCOMMODATE

Liquid Filler Technology with ZimaPack

Your filling process doesn’t have to be complicated to be good. Often, the less complex your filling process is, the more that can be done in a single machine – rinsing, capping, weighing – which leads to less stress and fewer waste products. At ZimaPack, we are at the forefront of innovation in automatic liquid filling machine technology. Our machines integrate advanced features such as VPN connection for remote support assistance and automatic door opening detection.

Our specialty is in net-weight filling solutions, ensuring precise and consistent fill levels regardless of bottle inconsistencies. This technology not only improves the quality of your product, but also reduces waste and increases efficiency. This allows you to get more product out in record times, with cleaner and more satisfactory results. Gone are the days of imprecise, over-filled bottles; with ZimaPack’s custom liquid filler technology, you’ll find yourself reducing waste and improving the quality of your products.

Every machine we build for your process is adaptable and scalable, growing with your business. From high-speed production lines to smaller batch operations, our equipment is designed to meet a broad spectrum of demands.

Adaptable and Scalable

At ZimaPack, we recognize that the key to adaptability is rapid evolution of your filling process and machine requirements. Our filling machines are highly adaptable, capable of a wide range of liquid types, from low viscosity beverages to high-viscosity creams and sauces.

This allows your business the ability to adapt to changing products, or scale with new production lines and higher-speed filling solutions. Starting with a core system that addresses your current needs, ZimaPack machines can be expanded and upgraded as your production requirements grow with you, allowing you to scale with ease. Whether you’re looking for increased capacity or additional features, we provide the solution for you.

Specialty Bottle Fillers / Sealer Machines

Every specialty bottle filler and sealer we design is tailored for your business’ specific packaging requirements. We offer a range of customizations, from filling of unique bottle shapes to handling of various cap types and sealing mechanisms.

No matter what you need, we can build it. Our custom-built machines are more cost-effective and easier for our team to produce than retrofitting stock machines. This enables you to create a custom solution that truly fits your needs. Our specialty bottle filling and sealer machines are capable of filling and sealing everything from small vials to larger containers with precision and care.

By integrating rinsing, capping, and filling into a single machine, your company is streamlining the packaging process, making it much more efficient and cost-effective than a retrofitted solution. At ZimaPack, we are here to work directly with you as a partner, not just providing equipment, but a comprehensive and customized packaging solution. With machine purchases, you also receive our premium support consultation and troubleshooting.

Custom-Built and Designed for Effective Processes

At ZimaPack, we don’t believe in delivering machines; we believe in providing custom-tailored solutions that fill your unique needs. Our custom-built and designed machines are focused on enhancing your existing production process effectively, and allowing you to scale and grow modularly with these machines.

We work closely with our clients through our consultation-based approach to understand your specific needs and challenges during the bottle filling process.

Based on these discussions, we design and build machines that are not just efficient and reliable, but integrate seamlessly into your existing product lines. These custom solutions can include adjustments in bottle size, filling methods, container handling systems, and software interfaces.

This bespoke approach ensures that you receive a filling solution that is not only effective, but also aligns perfectly with your operational objectives and long-term goals.

Premier Customer Support

At ZimaPack, we pride ourselves on offering more than just advanced filling machines, but an ongoing consultation partnership. Our premier customer support is a part of this commitment.

From the initial consultation, to our after-sales service, our team of experienced professionals is dedicated to ensuring your satisfaction with our machines.

After a machine purchase, we offer comprehensive customer support and service including responsive troubleshooting to ensure your machinery stays at the forefront of efficiency and scalability. Because we don’t keep any machines in stock and every machine is customized to your individual needs, every machine purchase grants access to dedicated support for that ZimaPack machine.

Filling System Issues to Consider

There are several filling system issues to consider before purchasing automatic liquid filling machines. Not only will these considerations tell you more about what you need, but you’ll also get the best fit for your needs.

First, capacity and speed are crucial. Your system must match your production volume and allow for future scalability. The compatibility of the machine with different bottle materials and sizes is important for this as well. While most machines only handle a limited type of materials or sizes, ZimaPack machines are able to handle glass, plastic, and aluminum bottles all on a single machine, offering an unparalleled versatility to your production line.

Furthermore, the accuracy of filling, operational ease, and maintenance requirements are all critical aspects to consider when adding a new machine to your production process. At ZimaPack, we help you navigate these considerations during the sales consultation, ensuring the system you choose is aligned perfectly with your operational requirements and production process goals.

Low VS. High Viscosity

Viscosity is a key factor in selecting the right filling machine for your production process. ZimaPack offers specialized solutions for both low and high-viscosity liquids.

For low-viscosity liquids, like water, juices, and other beverages, our machines ensure a fast, accurate, and splash-free filling process. Because everything fills by net weight, no over-filling is needed to ensure you meet the labeled requirements on the bottle.

On the other hand, for high-viscosity liquids like oils, syrups, creams, and sauces, you may need a different approach. Our machines are designed for these types of liquids as well, equipped with heavier-duty pumps and nozzles that can handle thicker products without compromising accuracy or efficiency throughout the process.

Best of all, with our machines, it’s easy to switch from one to another after cleaning; the precision in handling varying viscosities is a hallmark of our custom-tailored technology, ensuring that our machines deliver optimal performance regardless of your liquid filling needs.

Types of Bottles for Filling Machines

There are a wide range of bottles that you can use in filling machines depending on your product needs and industry requirements. Our machines can accommodate a wide range of bottles, designed with versatility in mind so that you can change bottle types based on your needs, whenever you want. We understand that packaging is not just about functionality, but also aesthetics and brand representation. Our machines are capable of handling everything from glass vials to plastic bottles and aluminum cans.

Glass bottles are ideal for beverages, spirits, and other types of premium products. Because glass bottles can require careful handling to prevent breaking on the production line, we ensure that our machines’ precision net weight filling won’t compromise the integrity of the glass.

Plastic bottles are versatile and durable, making them useful in a wide range of industries. Our machines can handle plastic bottle filling, from smaller containers to large jugs.

Aluminum cans are growing in popularity over plastic for their recyclability and lightweight handling, though the material can be thin before it is filled. Our machines are equipped to handle these materials smoothly, maintaining the quality and shape of the product pre-fill.

Fill Rate of Automatic Liquid Filling Machines

With sophisticated control systems that allow for quick adjustments and consistent fill rates, our machines are designed for high-speed operations without ever sacrificing accuracy. Depending on the viscosity of the liquid, our machines can be fitted with a range of nozzle types, optimizing the fill rate for each product. Calibrated to ensure each bottle is filled accurately and efficiently, you’ll experience reduced waste and maximized productivity across your product lines.

Automatic Liquid Filling Machine FAQ

What is the Use of an Automatic Liquid Filling Machine?

Automatic liquid filling machines are essential aspects of different industries, efficiently and accurately dispensing liquids into containers. Whether these contain beverage bottles or medicine vials, the primary use of these machines is to streamline the packaging process, significantly increasing productivity while maintaining consistency in fill levels.

These types of machines are versatile, handling a wide range of liquid types, from thin, free-flowing liquids to more viscous products like creams and sauces. Our net weight filling technology is more efficient and precise than the more common volumetric filling solutions, allowing ZimaPack machines to perform better and more reliably than stock filling machines.

Automatic liquid filling machines are crucial in a wide range of industries such as food and beverages, pharmaceuticals, cosmetics, and chemicals. By automating the filling process, these machines minimize human error, reduce waste, and ensure a faster turnaround, making them indispensable in modern production lines.

How Do Automatic Bottle Fillers Work?

Automatic liquid filling machines operate on a system that combines precision machines and advanced technology to repeatedly and accurately fill bottles – or other containers – with different types of liquids.

The typically begins with bottles being fed into the machine by a conveyor belt. From there, sensors detect the presence of the bottle and activate the filling mechanism. Once the bottle is underneath the dispensing nozzle, the machine dispenses the liquid  to a predetermined level by programmable logic controllers. While most machines use volumetric filling, ZimaPack has adapted this part of the process to include a much more accurate and precise net weight filling solution.

Once the bottles are filled, the bottles are capped and sealed. Typically, this would be done on separate machines, but with ZimaPack’s ability to customize individual machines, this can also be achieved within the same machine for small-batch or small-space requirements depending on your needs for efficiency.

How Many Types of Filling Machines Are There?

There are many different types of filling machines, and while there isn’t an exact number, there’s three separate categories where these machine types fall into; manual, semi-automatic, or automatic.

Typically, different types of filling machines are grouped by what they are designed to fill. Are they built to fill liquid, powder, gels, or something else entirely?

For liquid fill machines, there are a handful of various specializations, each designed to meet specific needs throughout the production process.

Manual and semi-automatic liquid filling machines are best used when a human touch is required to ensure quality control. Automatic liquid filling machines, on the other hand, come in different varieties based on how they are designed mechanically. Inline, rotary, and piston liquid filling machines are the most common.

Typically, stock machines are only designed to hold one type of filler technology. Piston fillers are designed specifically for high-viscosity products like creams and pastes. Inline fillers, on the other hand, are often built to integrate into existing production processes. These highly modular fillers can require some manual work to set up or change over to a new nozzle type. Rotary fillers are most often used for pharmaceuticals and beverages, and because they are on a rotary, they can be moved along with high-speed for high-volume production.

At ZimaPack, we custom-build our machines so none of these restrictions are a problem. Instead, you’ll enjoy a range of solutions based on your unique needs, and versatile technology that can accommodate anything you need filled, from low to high viscosity and virtually any container type.

Choose ZimaPack Today

Get in touch with our sales team today to learn more about our process and see which custom solutions are right for your production process today. With premier customer support and net weight filling, your product line will become more efficient with less waste and faster filling speeds. We make filling easy.

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What to Expect From Our Efficient Machines

Easy, Quick, Tool-less Change Parts

Changing components on our machines has never been this quick and straightforward, even without the need for tools. It is excellent for our customers that require more than one bottle or cap size. A snap-in change component allows for rapid, tool-free part insertion and removal. To make things quicker and more convenient for you, we offer options for dedicated cap chutes eliminating some change parts and allowing for faster changeovers.

Jam Detection System

In the event of a jam, we ensure that our jam-detecting system prevents the machine from continuing to rotate and causing any further damage. An alarm alerts the user to a jam via the machine’s screen with an illustration showing its origin or location.

Reject System

We can reject for incorrect weights, missing or crooked caps, missing foils, and quality control. The HMI screen (Human Machine Interface) can alarm and display the reject (these can also be shown in reports). A reject conveyor can be added so that the bottle can be safely guided onto a separate conveyor where an operator can collect and verify why it was rejected. The HMI will show why and a solution will be suggested to prevent further rejects.

Door Safety

When a machine door opens, the function immediately stops the machine from rotating. As soon as the machine comes to a halt, the screen will update to show which door is open. If the Filler is in the middle of filling a bottle it will continue to fill to the correct weight. Once the door is closed and the reset button is pushed the machine will continue to rotate.

User Access Levels

As a company, we place a high level of importance on the safety and security of our clients when they use our machines. Using your machine’s user access level feature, you can assign an Administrator, Operator, Manager, Technician, etc. Each assigned user will receive a user ID and password. Certain users can have access to all pages vs others can choose recipes/go into production but can’t make changes. This prevents operator errors, gives clear reports and helps with training!

The HMI screen and sync with a smartphone/tablet. Operators with access can use this feature to do anything the HMI screen does. Customizable reports are available on the HMI screen and can be downloaded or shared through an SD card and FTP server.

Custom Manual & How-to Videos

To ensure that our clients receive the best service and assistance, we create manuals and how to videos for each project or machine as a guide when operating.

Backed with Great Customer Service

We always listen to our clients and guarantee a same-day response. Rest assured that our team will resolve any issue as soon as possible. Remote troubleshooting is built into our software and allows us to access the machines quickly through a virtual private network (VPN) and sync with a smartphone /tablet for easy training/troubleshooting.