Piston fillers are widely used in the liquid filling industry for their simplicity, cost-effectiveness, and reliability. However, some users experience challenges with accuracy and consistency during operation. In this article, we address common concerns and provide recommendations to ensure optimal performance.
Common Issues with Piston Fillers and Their Causes
Real-World Case Study
A customer recently shared the following inquiry with us:
“Good day,
I would like to ask why these machines cannot be accurate when filing?
We have this machine from other company: https://www.vtops.com/product/semi-automatic-liquid-filling-machine/and we need another one, but it seems that it is not accurate when filling.
On one piston, we set the number 8 for 250 ml and on the second piston, we set it at 8.5 for 250 ml. Then for 1 liter liquid, we set one piston at 26 and the second piston at 26.7.Every next time we use the machine, we need to change the settings because it never remains the same. It is never the same.
If we buy the same machine from you, will it have the same problem?”
This case highlights some common issues encountered with piston fillers. Below, we analyze the potential causes and solutions.
- Inconsistent Filling Accuracy One common issue with piston fillers is the inconsistency in filling volumes, where identical settings on different pistons yield varying results. For example, one piston may be set to dispense 250 ml at “8,” while another piston requires a setting of “8.5” for the same volume.
Causes:- Air Pressure Fluctuations: Piston fillers rely on air pressure to drive the filling process. Inconsistent or unstable air pressure can result in varied output.
- Viscosity Changes: Variations in the viscosity of the liquid, often caused by temperature fluctuations, can impact filling precision.
- Component Wear: Over time, the seals, pistons, and cylinders may wear out, reducing the overall accuracy of the machine.
- Frequent Recalibration Another issue arises when users must recalibrate the machine for the same liquid every time they operate it. This can disrupt production efficiency and lead to frustration.
Causes:- Lack of routine maintenance or calibration checks.
- External factors such as temperature changes or impurities in the liquid.
How to Address and Prevent These Issues
1. Ensure Stable Air Pressure
- Use a high-quality air compressor and ensure a consistent pressure supply within the machine’s operational range.
- Regularly check and maintain air pressure levels to prevent fluctuations.
2. Perform Regular Maintenance
- Inspect and replace worn-out components such as seals and pistons to ensure consistent performance.
- Clean the machine thoroughly after each use to prevent residue build-up, which can affect accuracy.
3. Adjust for Liquid Properties
- Account for viscosity changes due to temperature by setting the machine appropriately.
- For liquids with varying viscosity, consider using advanced machines that can adapt to such changes.
- Add Mixing: Incorporate a mixing mechanism to prevent stratification caused by uneven density in viscous liquids, ensuring uniform filling results.
Advanced Solutions for Improved Accuracy
Weight-Based Filling Systems
Weight-based filling systems (Fill-by-Weight) measure liquids by weight rather than volume, eliminating the influence of factors like air pressure, viscosity, and temperature. This ensures consistent and precise filling every time. For industries requiring high precision, this is an ideal choice.
Servo-Driven Piston Fillers
For users who prefer to stay with piston fillers but want better accuracy, servo-driven piston fillers are an excellent upgrade. These machines integrate advanced servo motor technology, offering:
- Higher precision and repeatability.
- Reduced reliance on air pressure.
- Easier adjustment and programming for different liquid types.
Why Choose VTOPS Machines?
At VTOPS, we prioritize our customers’ needs and offer tailored solutions for various filling requirements. Here’s what sets us apart:
- Comprehensive Machine Inspection Every machine we ship is thoroughly inspected, calibrated, and optimized to meet your specific needs.
- 2-Year Warranty We provide a 2-year warranty on all our machines, ensuring peace of mind and long-term reliability.
- After-Sales Support Our dedicated team offers comprehensive after-sales service, including troubleshooting, maintenance guidance, and spare parts supply.
- Diverse Solutions Whether you’re looking for traditional piston fillers, servo-driven machines, or weight-based filling systems, we have the right solution for you.
Conclusion
Piston fillers are a great option for liquid filling, but to achieve consistent accuracy, addressing factors like air pressure, viscosity, and maintenance is crucial. For industries demanding high precision, advanced solutions like weight-based systems or servo-driven piston fillers can eliminate common issues.
If you’re considering upgrading your filling machine or need assistance with your current one, feel free to contact us. At VTOPS, we’re committed to providing the best machines and support for your production needs.
