Filling Machine
A filling machine transfers liquid products into containers such as bottles, cans, or cartons while preserving the physical and organoleptic properties of the product. Whether filling water, wine, beer, milk, oil, or juice, the machine must comply with all health and hygiene regulations while maintaining product integrity.
During the filling process, the machine must avoid four critical issues:
- Product contamination — no foreign substances entering the container
- Product oxidation — minimizing air contact, especially for wine and beer
- Quantity alteration — precise volume control for each container
- Quality alteration — preserving taste, aroma, and characteristics
The time between filling and capping must be as short as possible — measured in seconds — during which nothing should contact the product.
Types of Filling Machines
Linear Filling Machines
Linear fillers arrange filling valves in a straight line, suitable for lower to medium production speeds. These machines require less floor space and represent a lower investment compared to rotary systems.
Rotary Filling Machines
Rotary fillers position filling valves on a rotating carousel, delivering higher hourly production for industrial bottling operations. The number of filling valves determines output capacity.
Filling Methods
Different products require specific filling technologies based on their characteristics, carbonation level, viscosity, and preservation requirements:
Gravity Filling (Slight Depression)
Gravity filling allows product to flow into bottles by gravitational force through a valve activated when the bottle reaches the filling station. Air escapes through a vent tube, and filling stops when liquid reaches the tube's lower end.
After pre-evacuation, the filling valve opens and product flows gently without causing turbulence. Inert gas in the container returns to the tank during filling. When product level reaches the nozzle, filling stops automatically.
Ideal for: still wine, liqueurs, spirits in glass bottles
Vacuum (Depression) Filling
In vacuum filling, the filling nozzle seals the empty container and a vacuum pump removes internal air. The resulting vacuum pulls liquid into the bottle until reaching the predetermined level.
Ideal for: wine and spirits — no aroma or alcohol content loss
Volumetric Filling
Volumetric filling precisely measures liquid volume using a magnetic flow meter on one filling valve. Electronics calculate the time required for the desired quantity, and all other valves operate pneumatically based on this reference timing.
Ideal for: products requiring precise volume control
Isobaric (Counter-Pressure) Filling
Isobaric filling machines maintain equal pressure between tank and bottle, essential for carbonated products. Benefits include:
- Optimized filling cycles reducing downtime
- No degassing required at various production stages
- Zero oxygen increase in wine
- Improved filling quality with reduced energy consumption
Ideal for: champagne, spumante, sparkling wines, carbonated drinks, still wines with overpressure
Hot Filling
Hot filling processes products at temperatures between 80°C and 85°C, followed by nitrogen injection to prevent implosion during cooling. The product's heat sterilizes the container directly.
Ideal for: products with 7-10 day shelf life — tomato purée, fruit juices with high organic content, milk, cream
Aseptic Filling
Aseptic filling operates in a completely sterile, sealed environment. Food and packaging are sterilized separately and combined under aseptic conditions in a germ-free space.
Ideal for: sensitive products without natural protection against microorganism proliferation
Filling Methods Comparison
| Method |
Principle |
Best Applications |
| Gravity |
Gravitational flow with vent tube |
Still wine, liqueurs, spirits |
| Vacuum |
Vacuum pump creates depression |
Wine, spirits (aroma preservation) |
| Volumetric |
Magnetic flow meter measurement |
Precise volume applications |
| Isobaric |
Equal pressure tank/bottle |
Carbonated drinks, sparkling wine |
| Hot fill |
80-85°C with nitrogen injection |
Juices, purées, dairy |
| Aseptic |
Sterile sealed environment |
Sensitive products, long shelf life |
Filling Machine Construction
The filler requires maximum attention given its critical role in product safety. Essential requirements include:
- Food-grade stainless steel construction throughout
- Sanitizable design allowing complete cleaning access
- Food-safe spare parts — rubber seals, gaskets, and metal components
- Variable number of filling valves or nozzles based on production requirements
Regular scheduled maintenance by competent technicians ensures high production standards and extended machine life.
Filling Monoblocks
A filling monoblock (or triblock) combines multiple machines into a single integrated unit. Standard configurations include:
- Rinser + Filler + Capper — most common triblock arrangement
- Filler + Capper — basic monoblock configuration
- Multiple capping systems — for different closure types
The monoblock handles three essential bottling functions: rinsing, filling, and capping in immediate sequence, minimizing the critical time between filling and closure.
Purchasing Used Filling Machines
Used filling machines offer significant advantages for bottling operations, with potential savings of 35% to 60% compared to new equipment. Key factors to evaluate before purchase:
- Working hours — indicator of remaining service life
- Maintenance history — regular service by specialized technicians
- Overhaul status — mechanical and aesthetic condition
- Production requirements — matching machine capacity to actual needs
- Product compatibility — appropriate filling method for your application
Common reasons for upgrading filling equipment include increased production demands, machine inefficiency causing stops or slowdowns, and difficulty reaching required daily production volumes.
