System Description, Operating Principle, Technical Specifications, and Application Areas
Level-controlled liquid filling systems, inside each bottle or package during the filling process ensuring that there is a visually equal level of liquid. These are automated systems. In this system, instead of volume, the amount of liquid in the container is considered. height and overflow point This method is taken as a basis. This method is particularly important. transparent or semi-transparent packaging In the sectors where they are used, they are preferred to protect the shelf aesthetics and consumer perception of the products.
In these systems, the filling process is done either by a overflow nozzle, or submersible and level-controlled valve system This is achieved by reaching a specific height, not by filling time or volume. Excess liquid is recovered back into the main tank system via special return lines, thus minimizing product loss.
Viscosity Matching and Product Behavior in Level Controlled Systems
These systems generally high fluidity (low viscosity) They are ideal for liquids because these products provide a smooth flow with overflow or submersion nozzles, and level detection is possible. Medium viscosity liquids, For example, lotion-based liquids can be successfully filled using nozzles that provide controlled flow.
However high viscosity, This system is not recommended for products such as honey, glucose, and cream. This is because it is technically difficult for the filling process to naturally stop or for the system to return to the overflow line when these products reach the overflow point.
Viscosity Level | Compatibility Status | Typical Product Examples |
Low (1–10 cP) | It operates at maximum efficiency and speed. | Water, fruit juice, toner, surface cleaner |
Medium (10–500 cP) | Success can be achieved with the right nozzle. | Shampoo, shower gel, liquid soap, antiseptic |
High (>500 cP) | Inefficient, not recommended. | Honey, glucose, rich sauces, medicinal creams |
Technical Specifications
Technical Parameters | Explanation |
Working Principle |
Level-based overflow, vacuum, or sensor-controlled filling. |
Filling Range | 150 ml – 5,000 ml (configured according to packaging) |
Sensibility | ±2% (optical visual consistency is targeted) |
Capacity | 800 – 4,000 units/hour (filling time depends on liquid properties) |
Nozzle System | Overflow nozzles, vacuum level control systems, submersible versions. |
Packaging Compatibility | Glass, PET, HDPE, PP – especially clear and semi-transparent bottles. |
Body Structure | AISI 304 or 316L stainless steel, GMP compliant, IP65 protection. |
Control Unit | Industrial PLC + HMI touchscreen control panel |
Return Line | Automatic diversion of overflowing product to the tank (with optional valve) |
Cleaning Harmony | CIP-compliant structure (Clean-In-Place), fast turnaround and product changeover. |
Energy Consumption | 220–380 V AC, 50/60 Hz |
Pneumatic Requirements | 5–6 bar compressed air (in valve systems) |
Optional Modules and Integrations
Level-controlled filling systems can be supplied with a variety of optional modules that can be integrated into modern filling lines:
- ✔️ Bottle positioning and separation star wheel
- ✔️ HEPA filter cabinet for aseptic production environment.
- ✔️ Automatic lid feeding, screwing, and torque-controlled lid closing systems.
- ✔️ Conveyor transfer and transition modules
- ✔️ Slow-rising immersion nozzles for foaming products.
- ✔️ Product return line (for recovering spilled liquid)
- ✔️ Integrated with speed-controlled motor and frequency inverter.
- ✔️ Digital interfaces for SCADA / remote control and data logging.
Application Areas and Typical Products
Sector | Product Types |
Food & Beverage | Bottled water, flavored drinks, fruit juice, iced tea |
Cosmetic | Toner, liquid soap, shower gel, hair conditioner |
Household and Industrial Cleaning | Windshield washer fluid, surface cleaner, liquid detergent |
Agricultural Products | Liquid fertilizer, foliar nutrient in transparent packaging. |
Medical / OTC | Alcohol-based solutions, antiseptics, disinfectants |
Why should you choose a Level Controlled Filling System?
- 🔹 It guarantees shelf aesthetics.Even though the bottles have different volumes, they present the same level of filling appearance.
- 🔹 It is advantageous in terms of cost.It has a simpler mechanical structure compared to volumetric systems.
- 🔹 Clean working principleExcess product is recovered, minimizing waste.
- 🔹 Suitable for high-speed production.It is particularly preferred in sectors requiring rapid filling, such as beverages and cleaning products.
- 🔹 It provides controlled filling to prevent foaming and overflow risks.
- 🔹 Suitable for hygienic production areas., It can be designed in accordance with GMP and CE standards.