Like any other type of machinery, inline liquid filling equipment is vulnerable to wear and potential breakdowns. If you want to keep your equipment in good shape, there are certain mechanical malfunctions to look out for and address before they hinder your entire production line. There are several specific types of problems that can affect liquid filling machines.
Foaming and Dripping
If you're experiencing foaming or dripping problems with your liquid filling machinery, inadequate seals are likely the issue. Dripping and foaming can waste liquids and result in expensive loss of product over time, but this issue is preventable by simply tightening seals and making sure that valves don't leak during or after the filling process is completed. If the seal is irreparable, you may need to replace the entire filling machine.
Foaming issues may require the use of a diving nozzle, however. The diving nozzle in foamy liquid filling applications reaches the bottom of the container during the filling process, virtually eliminating foaming problems.
Inaccurate Filling Levels and Timing
Another potential problem that can result in wasted product and an overall inadequate liquid filling line is inaccuracy of filling and timing. If filling levels are incorrect, this can either result in overflowing and wasted product, or insufficient filling of containers to result in a surplus of product.
One of the common causes of inaccurate filling levels is a bad seal. Check for wear and tear on seals, which may require replacement if tightening them doesn't work. Spacers may also be the source of filling level issues, along with air hoses with low or high air pressure. Performing routine maintenance checks on hose barbs and other parts that may be loose or allow air into product pathways can help you avoid this. Certain machines may include a touchscreen that allows for volumetric filling adjustments depending on the product. Inaccurate timing is another issue that is usually resolved by changing operational settings rather than adjusting equipment hardware.
Keep in mind the product's viscosity, as this can also affect volumetric fill settings.
Unlike the previous issues, insufficient power doesn't have to do with the equipment as opposed to the facility itself. To resolve power issues, you should take certain steps to make sure that you can avoid power surges and supply enough power to circulate evenly among your machinery. Power surges can be particularly detrimental for your production line, causing a complete breakdown that can result in a complete loss of productivity or, if it lasts long enough, product spoilage.
Make sure your facility has a backup generator and enough power to handle each piece of equipment you introduce in your liquid filling line. This will help ensure that your equipment operates at its most efficient and avoids potentially costly breakdowns.
Perform Regular Preventative Maintenance Checks
One of the best ways to avoid these common mechanical issues is to check machinery for defective or malfunctioning parts on a regular basis. Develop a maintenance schedule that works for you to prevent these issues from causing damage to your liquid filling operations and losing money in the process. If you're unsure about which parts of your liquid filling assembly require attention or need help identifying issues, you can consult an industry expert to help you monitor your equipment's condition.