The Benefits of Filling to a Level

Filling to a level is achieved by using the popular Overflow Filling Machine from Liquid Packaging Solutions. While some liquid fillers will fill to a certain volume, or even a certain weight, the overflow filler will fill containers to the same level regardless of the interior volume from bottle to bottle.

Filling to a level has several benefits in the packaging world. For starters, anyone who packages in a clear glass or otherwise transparent bottle or container will improve their shelf impact by filling every container to the same level. But this boost in aesthetic value is not the only value.

Overflow fillers also help to control foamy products simply by the way they fill the containers. Special nozzles are used on an overflow filler that both dive in to the bottle and seal the opening to allow the repeatable level fill. Once nozzles are in the bottle, liquid is released and flows until it reaches the target, at which point the liquid enters an overflow port and typically returns to the holding tank. The process of overflowing allows the fill time to be slightly increased to force foam out of the bottle, ensuring levels don't change when foam settles if left in the bottle.

In most cases, the overflow filler, by virtue of allowing product to flow back in to the supply or holding tank, also reduces or eliminates product waste during the packaging process. Where recirculation would be an issue, the overflow can also be redirected to a separate tank or a waste area as well.

One concern many packagers have revolves around the possibility of varied volume from bottle to bottle, as some industries or products need to stay within a range or tolerance of volume. While it is true that volume may vary, most bottle manufacturers have a creation process that keeps the interior volume close from one bottle to the next. However, packagers should check with their bottle manufacturer to confirm that they will not experience a wide variation in the interior volume of containers. Overflow fillers also work better with free-flowing products, as thicker viscosities can lead to longer fill time and can make the filling process inefficient. These machines can also work with some particulates, though larger chunks or pieces in a liquid can lead to clogged nozzles or return points.

To learn more about overflow filling machines, from tabletop to fully automatic, visit the Overflow page of the Liquid Packaging Solutions website under Filling Machinery, or contact a Packaging Specialist at LPS today!