How this product class behaves
The typical process uses ATEX-assessed gravity, pump, peristaltic or flowmeter filling system supplied through bonded and earthed closed transfer with vapour management. The equipment should be configured to classify the area and select electrical, pneumatic and mechanical equipment accordingly.
Before discussing speed or automation, define the actual operating window: minimum and maximum dose, product temperature, density, viscosity or bulk density, inclusions, foam, shear sensitivity, corrosivity, pack dimensions and closure. A single nominal sample is not enough for a robust specification.
Recommended filling technologies
Primary route
Atex-assessed gravity, pump, peristaltic or flowmeter filling system.
Product supply
Bonded and earthed closed transfer with vapour management.
Critical control
Classify the area and select electrical, pneumatic and mechanical equipment accordingly.
Temperature and product condition
Well below relevant flash-point and stability limits. Temperature changes may alter viscosity, foam, gas breakout, dose accuracy, closure performance or pack stability. Define where temperature is measured and the permitted deviation.
Cleaning, changeover and material compatibility
Plan for safe solvent recovery, ventilation and line clearance under an approved procedure. Product-contact materials, elastomers, lubricants, surface finish and drainage should be reviewed against every formulation. Include safe access, line clearance, product recovery and waste handling.
Principal production risks
Risk focus
Vapour ignition, static discharge, spills, worker exposure and incompatible materials. The process and machinery risk assessments should cover normal running, refill, sampling, adjustment, blockage clearance, cleaning and maintenance.
What to prove in a product trial
- Repeatable dose at minimum and maximum line speed
- Clean cut-off and acceptable pack presentation
- Stable product feed through refilling and batch end
- Changeover and cleaning time using the intended method
- Closure, label, code and distribution performance after filling
Example product applications
White Wine Vinegar in Glass Bottles
Flammable or solvent-based liquid
Edible oils & vinegarsWhite Wine Vinegar in Metal Cans
Flammable or solvent-based liquid
Edible oils & vinegarsWhite Wine Vinegar in Approved Plastic Bottles
Flammable or solvent-based liquid
Edible oils & vinegarsWhite Wine Vinegar in Jerrycans
Flammable or solvent-based liquid
Edible oils & vinegarsWhite Wine Vinegar in Drums
Flammable or solvent-based liquid
Edible oils & vinegarsRed Wine Vinegar in Glass Bottles
Flammable or solvent-based liquid
Edible oils & vinegarsRed Wine Vinegar in Metal Cans
Flammable or solvent-based liquid
Edible oils & vinegarsRed Wine Vinegar in Approved Plastic Bottles
Flammable or solvent-based liquid
Edible oils & vinegarsRed Wine Vinegar in Jerrycans
Flammable or solvent-based liquid
Edible oils & vinegarsRed Wine Vinegar in Drums
Flammable or solvent-based liquid
Wines, spirits & liqueursLondon Dry Gin in Glass Bottles
Flammable or solvent-based liquid
Wines, spirits & liqueursLondon Dry Gin in Metal Cans
Flammable or solvent-based liquid
Common questions
Which filling machine suits a flammable or solvent-based liquid?
A ATEX-assessed gravity, pump, peristaltic or flowmeter filling system is the normal starting point. Final selection depends on dose, accuracy, product feed, temperature, pack, cleaning, contact materials and required output.
Why are product samples needed before specifying a filler?
Published viscosity or density values do not show aeration, particles, stringing, shear sensitivity, temperature effects or interaction with the nozzle and pack. A representative test exposes these issues before manufacture.
Can one machine cover several product viscosities or formats?
Often yes, within a defined operating window. The specification should identify the easiest and most difficult products, smallest and largest doses, every pack height and diameter, and the acceptable changeover method.
How is filling accuracy confirmed?
Agree whether the target is volume or mass, the permitted tolerance, test method and sampling frequency. Measure warm-up, hopper refill, speed changes and end-of-batch conditions rather than only stable running.
What determines the real line speed?
The slowest repeatable operation governs output. Product refill, container loading, filling time, closure handling, label application, rejects, accumulation, cleaning and operator intervention all affect the sustainable rate.