How to use the result
Head count follows the real cycle
A filling head does not fill continuously. Containers must arrive, settle, be detected, fill, stop cleanly and leave the station. Diving nozzles, bottom-up filling, multi-stage speed profiles and long product tails increase the cycle. Time the complete repeatable cycle rather than using only pump or piston discharge time.
Check physical nozzle pitch
The calculated head count must fit over the pack pattern. Very wide containers, irregular neck positions, closely spaced closures or limited conveyor length can make the theoretical number impractical. A machine may need staggered filling, a longer index or a different handling concept.
Confirm product-feed capacity
Adding nozzles does not increase output if the balance tank, pump, hose, manifold or upstream process cannot supply the combined instantaneous flow. Pressure variation can also cause head-to-head inconsistency. Test all heads together at the largest intended dose.
Common questions
How many filling heads do I need?
Divide the required rate, including capacity margin, by the effective output available from one head using the complete fill-and-index cycle and a realistic efficiency.
Will twice as many heads double output?
Only when product supply, container handling, closing and downstream equipment can sustain the additional rate.
Should future growth be included?
A documented capacity margin can avoid immediate replacement, but unnecessary heads add cleaning, maintenance and change-part complexity.
Can one machine cover very different dose sizes?
Often yes, but the minimum and maximum dose, cylinder or pump range, nozzle size and cycle time should be proven for every extreme.