包装技术基础(双语教学)20.ppt

Lesson20 FillingSystems第20课充填灌装系统 content IntroductionLiquidFillingLiquidVolumetricFillingLiquidConstantLevelFillingDryProductFillingDryVolumetricFillingDryFillingByWeightFillingByCount Introduction 1 Whatafillercanbeaskedtodo Fillers fillingmachines areusedtotransfermanytypesofproductsfrombulkstoragebinsandvatsintothecontainersinwhichtheyfindtheirwaytothemarket Thegreatvarietyofproductsthatarepackagedandthecontainersthattheyfillhascausedthedevelopmentofalargenumberofprocesses techniques andmachinesthatareusedforproductfilling 2 ConsiderationsinselectingafillerTypesofproducts fromverythinliquidstosemi liquidproducts pastes andsolids stable volatile explosive hot frozenproducts Size shape andconstructionofthecontainers glassbottlesandjars plasticbottlesandcartons paperboardboxes metalcans andplasticorpaperbags Waytheproductismeasured byvolume weight orcount Introduction Introduction Desiredspeedoftheoperation arelativelyslowmanualoperation semi automatic fullyautomatic highspeedlines SpecialhandlingrequirementsoftheproductCostofinstallationOperation LiquidFilling 1 IntroductionLiquidproducts alcoholandsodawaterSemi liquidproducts toothpaste peanutbutter andcaulkingcompound LiquidFilling 2 TypesofFillingMachinesThecontainersmaybemadeofplastic metal glass treatedpaperboard oranumberofothermaterials Theshapesofthecontainersincludethoseofbottles jars vials tubes cans pouches cartons anddrums Figure20 1 Figure20 1Theshapesofthecontainers LiquidFilling Mostliquidandsemi liquidproductsarefilledbyoneoftwomajormethods volumetric orconstantlevelfilling Involumetricfillingtheamountofproductispremeasuredsothateachcontainerhasthesamevolumeofproduct Constantlevelfillingtechniquesfilleachcontainertothesamelevel soitisfrequentlycalledthe fill to a level method LiquidFilling LiquidFilling 3 UseofFillingMachinesVolumetricfillingisparticularlyappropriateforapplicationsinthepharmaceuticalindustrywhereitisimportantthateachcontainerisaccuratelyfilledwithaspecificvolumeofproduct Constantlevelfillingisusedwithsee throughbottlesinwhichitisimportantthatallofthebottlesinadisplayappeartobefilledtothesamelevel althoughthebottlesmaynotbeexactlythesamesizeandthevolumesmaybeslightlydifferent LiquidFilling 4 RotaryandStraight lineFillersTherotaryfillerremovesthecontainersfromtheconveyorontoarotatingplatewhichcarriestheminacirclethroughthefillingmachines Thefillingheadsrotatewiththecontainersastheyarefilled sothatthereisacontinuousmotion Figure20 2 Figure20 2Rotaryfilling 动画 LiquidFilling Thestraight linefillersfilleachcontainerasitmovesalongtheconveyorinastraightline a Thismaybeanintermittentmotionoperationinwhichtheconveyorisstoppeduntilthecontainerisfilled thenitismovedjustfarenoughtoplacethenextcontainerinpositionunderthefillingnozzle b Itmayfillonlyoneoranumberofcontainersineachoperationdependinguponthenumberoffillerheadsthatareused LiquidFilling c Somemultipleheadmachineshavethecapabilityoffollowingthecontainersalongthelineandfillingtheminacontinuousmotionwithoutstoppingthefillingline Figure20 3 Figure20 3Straight linefilling 动画 LiquidVolumetricFilling IntroductionDefinition Volumetricfillersdeliverapremeasuredvolumeofproducttoeachcontainer andthevolumeofproductineachcontainerisheldconstant Advantages accuracy flexibility andreliabilityinadditiontobeingrelativelyeasytoclean Threepopulartypesofvolumetricfillingmethods pistonoperation diaphragmaction andtimedflow LiquidVolumetricFilling 1 PistonVolumetricFillingApistonfiller Figure20 4 measuresanddeliverstheproducttothecontainerbytheactionofasinglepistonforeachfillerhead Empty Filling Figure20 4Pistonvolumetricfillingwithrotaryvalve LiquidVolumetricFilling Figure20 5Pistonvolumetricfillingwithreciprocatingvalve 动画 LiquidVolumetricFilling Typesofvalves areciprocatingvalveandarotatingvalve Figure20 6 Rotaryvalve Reciprocatingvalve Figure20 6Valves LiquidVolumetricFilling Thevolumeofproductdeliveredintothecontainerisdeterminedbythevolumeofthefillingchamberinwhichthepistonisoperating Thisvolumecanbechangedbyadjustingthelengthofthepiston sstroke Asthestrokeislengthened thevolumeofthechamberisincreased andasthestrokeisshortened thevolumeofthechamberisdecreased Figure20 7 LiquidVolumetricFilling Shortpistonstroke Longerpistonstroke Figure20 7Volumeadjustment 动画 LiquidVolumetricFilling Figure20 8showsthreemethodsthatareusedtokeeptheproductfromleakingoutaroundthepistonasitmovesbackandforth finetolerance ringsplacedingroovesaroundtheircircumferenceandcuffsappliedtotheendsofthepistonstocreateaseal LiquidVolumetricFilling Machinedsurface Rings Cuffs Figure20 8Threemethodstokeepproductfromleakingoutaroundpiston LiquidVolumetricFilling Differenttypesofproductsrequiredifferentnozzledesignsandsizes Figure20 9 Fillernozzlesaredesignedindifferentsizesandshapestopreventsplashing foaming orexcessiveaerationoftheproductsduringfilling LiquidVolumetricFilling Figure20 9Nozzletypes 动画1动画2动画3动画4 LiquidVolumetricFilling 2 DiaphragmVolumetricFillingThediaphragmtypevolumetricfillerusesaflexiblediaphragmandpneumaticpressuretomovepremeasuredamountsofproductfromthesupplytankintoacontrolledvolumechamberandintothecontainer Thediaphragmvolumetricfillingsystemsaregenerallyusedtofillsmall neckedbottleswithrelativelyexpensiveproductsbecauseoftheirhighlevelofaccuracyandthesmalllossofproductinfilling LiquidVolumetricFilling Figure20 10Diaphragmvolumetricfiller 动画 LiquidVolumetricFilling 3 TimedFlowVolumetricFillingThevolumeofproductineachfillcanalsoberegulatedbycontrollingtheamountoftimetheproductflowsataconstantratethroughastandardsizedtubeintothecontainer Threepopularwaysofmeasuringandregulatingtheflowtimearerotatingmeteringdiscs rotarypumps andaugers LiquidVolumetricFilling 1 RotatingMeteringDiscsThefillingheadconsistsoftwostationaryplatesandabottomrotatingplate Figure20 11 Whentheopeningsinthethreeplatesareinalignment theproductisfreetopassthroughintothecontainer Theflowceaseswhentherotatingbottomplatemovesoutofposition LiquidVolumetricFilling StationaryTopPlateStationaryTeflonPlateRotatingBottomPlate Filling Filled Figure20 11Rotatingmeteringdiscs LiquidVolumetricFilling Thevolumeofthefillcanberegulatedbychangingthesizeoftheopening orslot inthecenterplateorbychangingthespeedoftherotatingplate Thisfillercandoublefillacontainerbypassingitundertwostations ortwoormoredifferentmaterialscanbefilledintothecontainerbysupplyingdifferentproductsatthedifferentfillingstations Thevolumetricfillerusingmeteringdiscscanhandleawiderangeofliquidproductsandsomesemi liquidproductsthatmaybeasthickaspeanutbutter LiquidVolumetricFilling 2 RotaryPumpsRotarypumps Figure20 12 areusedforvolumetricfillingbyregulatingtheoperatingintervalofthepumptocontroltheamountofproductthatisdelivered Figure20 12Rotarypumpfiller 动画 LiquidVolumetricFilling Theproductflowiscontrolledbyelectricorairoperatedclutchandbrakemechanismsthatcanstartandstopatverypreciseintervals Somefillersmeasuretheproductflowwitharevolutioncounterattachedtothedriveshaftofthepump andtheflowisregulatedbyadjustingthenumberofturnsthatthepumpimpellersmakeoneachfill LiquidVolumetricFilling 3 AugersSemi liquidproductsthataretoothicktobemovedbyarotarypumpmaybefilledbyasimilarfillerthatusesanaugerinplaceofthepumptomovetheproduct Thevolumeofproductdeliveredbyanaugerfiller Figure20 13 iscontrolledbytheamountoftimetheaugerturnsorthenumberofturnsitmakesoneachfill inmuchthesamemannerthatisusedforrotarypumps Someaugerfillersuseanagitatorrotatingintheproducthoppertokeeptheproductmovingsmoothlyandmaintainanevenconsistency LiquidVolumetricFilling Figure20 13Augerfiller LiquidConstantLevelFilling IntroductionItisfrequentlydesirabletohavethefilllineatthesameheightoneachcontainersothatallofthemappeartobefilledexactlythesamewhentheyareonthedisplayshelf Somemanufacturersdeliberatelyaddextraproductandoverfillsomeoftheir seethrough containersinordertoimprovetheirappearanceandtoguaranteethatallofthemcontainatleasttheminimumdesiredamountofproduct Constantlevelfillingtechniquescompensatefortheminorchangesandvariationsinthecontainersandproducetheuniformappearancethatisimportantinthesaleofmanyproductsin seethrough containers LiquidConstantLevelFilling Fivebasicmethodsusedforconstantlevelfillingofstillliquidsandsemi liquids PuregravityfillingPurevacuumfilingGravityvacuumfilingPurepressurefillingLevelsensingfillingOnemethodusedforfillingcarbonatedproducts Pressuregravityfilling LiquidConstantLevelFilling 1 PureGravityFillingBeingnotonlyoneoftheoldestandsimplestconstantlevelfillingmethods butitisalsooneofthemostaccurateonesforfillingfree flowingproducts Figure20 14 Usedformoststillliquidsandsomesemi solids Theproductflowisproducedbylocatingtheproductsupplytankhighenoughsothatforcesofgravitycanbeusedtomovetheproductthroughthefeedmechanismsintothecontainers LiquidConstantLevelFilling Figure20 14Puregravityfilling 动画 LiquidConstantLevelFilling Themaintenancerequirementsarerelativelysimple Theconsistencyoftheproductandthefreemovementofallmovingpartsarecriticalforsmoothoperation LiquidConstantLevelFilling 2 PureVacuumFillingUsedprimarilyforfillingnarrowneckedglassbottleswithstillliquids Figure20 15 Notnormallyusedwithplasticorothernon rigidcontainers Generallyfasterthanapuregravitysystem buthassomeoverflowandrecirculationofproduct Thevacuumfillerworksonlywhenthereisasealbetweenthebottleandfillervalve sochippedorcrackedbottlescannotbefilled LiquidConstantLevelFilling Figure20 15Purevacuumfilling 动画 LiquidConstantLevelFilling Avacuumlevelofbetween25and28inchesofmercuryisnormallymaintainedtoprovidesmoothandefficientoperation Somewhatmoredifficulttocleanthanasimplegravitysystembecauseofitscomplexityandsmallvacuumtubesthatcanbecomeplugged Thepropertypeoffillingnozzleisalwaysusedfortheproductbeingfilled becausefoaming aeration andsplashingcanbeincreasedbyrapidmovementoftheproduct LiquidConstantLevelFilling 3 GravityVacuumFillingCombiningthefeaturesofboththegravityandthevacuumsystems Figure20 16 Alightvacuumoffrom3to5inchesofmercuryismaintainedinthesystemtoassistindrawingtheairoutofthecontainersandtostabilizetheflowoftheliquid Havingnottheoverfloworrecirculationofproductthatisinherentinthepurevacuumsystem anditproducesminimumamountsofturbulenceandaerationoftheproduct LiquidConstantLevelFilling Particularlywellsuitedtofillingdistilledspiritsandwinebecausethereisvirtuallynolossofproof Achippedorcrackedbottleonwhichasealisnotformedwillnotbefilled LiquidConstantLevelFilling Figure20 16Gravityvacuumfilling LiquidConstantLevelFilling 4 PurePressureFillingTheproductispumpedfromastoragetankthroughafillingvalveandintothecontainer Figure20 17 Figure20 17Purepressurefilling 动画 LiquidConstantLevelFilling Whentheproductreachestheoverflowport thefilliscompleted buttheflowcontinuesthroughtheoverflowtubeuntilthesealonthecontainerisbrokenandthevalvesleevecoverstheportsinthefillingnozzleandstopstheflow Normallyusedforstillliquids butitcanbeappliedtoawidevarietyofproductswithdifferentconsistencies LiquidConstantLevelFilling Applyingpressuretotheproductmaytendtoincreasesplashingorfoaming Regularcleaningandlubricationofallmovingparts LiquidConstantLevelFilling 5 LevelSensingFillingMakingitpossibletofillcontainerstoalevelwithoutestablishinganairtightsealbetweenthetopsofthecontainersandthefillervalves Figure20 18 Figure20 18Levelsensingfilling 动画 LiquidConstantLevelFilling Usedprimarilyforhighspeedfillingofsmallneckedplasticandglassbottles Thefilllevelisveryaccurate andthereisnoneedforproductrecirculation Thesensingdeviceoperatesbydirectingastreamoflowpressureairatthefillingstationanddetectingchangesintheresistancetotheairflow Thepositioningofthefillerandthestartoftheflowcanbeinitiatedwhenthesensingdevicedetectsthepresenceoftheemptybottleinthefillingstation Whentheproducthasfilledtothedesiredlevel thesensingunitsignalstheinterfacevalvetostoptheflow LiquidConstantLevelFilling 6 PressureGravityFillingPressuregravityfilling Figure20 19 isaprocessthatwasdevelopedspecificallytohelpholdtheCO2inthecarbonatedbeveragesduringthefillingoperation Thismethodisusedalmostexclusivelyforfillingbeveragessuchassodas beer sparklingwines andchampagnesintobottlesorcans Apressureofbetween15and125psigismaintainedintheheadspaceoftheproductsupplytanktohelpholdtheCO2insolution LiquidConstantLevelFilling Filling Filled Figure20 19Pressuregravityfilling 动画 LiquidConstantLevelFilling Whenthecontainerissealedtothefillingvalveamechanicallatchopensachargingvalveatthetopofthevalveventtube Thisestablishesinthecontainerthesamepressurelevelthatisbeingappliedtothesurfaceoftheproductinthesupplytank Theproductisinatotallypressurizedenvironment Thispressuredoesnotinterferewiththefillingprocess butitdoespreventthelossofcarbonation LiquidConstantLevelFilling Afterthepressureinthecontainerisequalizedwiththatinthesupplytank thespringloadedfillervalveopensandtheproductflowsintothecontainerbygravityuntiltheventportiscoveredandtheflowisstoppedasinanormalgravityfillingprocess Thefillingvalvealsocontainsamechanicalsniftportwhichopenstheheadspaceofeachfilledcontainertotheatmosphereinordertogentlyreleasethepressurefromthefilledcontainerandpreventgushingwhenthesealisbrokenandthefillerheadisremovedfromthecontainer DryProductFilling 1 IntroductionDryproducts light heavy sticky verydry flowingfreely somemovedbyforce Thecontainers assmallasacapsuleoraslargeasaonehundredpoundbagora55gallondrum Theycanbeboxes cans bottles pouches bags drums orotherforms andtheymaybemadeofavarietyofrigidandflexiblematerials DryProductFilling 2 TypesofDryProductsRiceandbeans arefreeflowingandeasytomove Finepowders confectionerssugar maybehardtocontaininthebinsorcontainersandcancauseadustyorexplosiveatmosphere Nails bolts andotherhardwareitemsmayrequirespecialhandlingbecauseoftheirweight bulk orshape Cornflakesandlightbulbsmustbeprotectedfrombreakageduringpackaging Icecreambarsmustnotbeallowedtomelt Specialcareisneededtokeepfoodpackagingsanitaryanddrugssterile DryProductFilling 3 TypesofDryFillingOperationsTherearefourbasictypesofdryfillingmachinesbaseduponthewaytheamountofproductbeingdeliveredismeasured Byvolume thevolumetricfillersdeliveraconstantvolumeofproducttoeachcontainer Bynetweight thenetweightfillerweighstheproductbeforeitisdeliveredintothepackage Bygrossweight thegrossweightfillerweighstheproductinthecontainer Bycount thecounterplacesthesamenumberofitemsintoeachcontainer DryProductFilling 4 ProductDeliveryFreeflowingdryproductsarefrequentlydeliveredtothefillingmachinethroughgravityfeedsystem Otherproductsaredeliveredbyvibratorsystemsinwhichvibratingpanscausetheproductto walk intothefiller Augersareusedtomovethenonfree flowingproductsthatarestickyorhaveothercharacteristicsthatmakethemdifficulttohandle DryVolumetricFilling IntroductionLoadinganexactvolumeofproductintoeachcontainerwithoutconsiderationoftheproduct sdensityorweight Deliveringaconstantvolumedoesnotalwaysproduceaconstantweight Fourpopulartypesofvolumetricfillersusedwithdryproductsare Cuporflaskfillers Floodingorconstantstreamfillers Augerfillers Vacuumfillers DryVolumetricFilling 1 CuporFlaskFillersGettingitsnamefromthecuporflaskthatisusedtomeasuretheamountofproductthatisdelivered Figure20 20 Thesidesofthecupstelescopesothatthecupsizecanbeadjustedtotheexactvolumethatisneeded DryVolumetricFilling Figure20 20CuporFlaskFillers 动画 DryVolumetricFilling Workingparticularlywellwithfree flowinggranularproducts Normallyusedforproductsinwhichthedensityorunitweightisrelativelyconstantorwhenthevolumeoftheproductthatisdeliveredismoreimportantthantheweight Usuallyusedwhenthesizevariationsarerelativelysmallorthegainedspeedandeconomymorethanoffsetthecostoftheextraproductthatisbeingused Figure20 21showsatopviewofatwelveheadrotaryfillerwithascaleononecup Machineadjustmentsmayoccasionallybeneededtocorrectconditionsofunderfill overfill excessiverecirculation orspillageatthecontainer DryVolumetricFilling Figure20 21Rotaryfillerwithfeedbackscale topview DryVolumetricFilling 2 FloodingorConstantStreamFillersThefillersworkontheprinciplethatcontainerspassingunderaconstantstreamofproductinthesameamountoftimewillallreceivethesameamountofproduct Figure20 22 Anyvariationsinthespeedofthecontainerasittravelsunderthefilleraffectsthevolumeofthefill Changesintherateofproductflowfromthehoppercanalsoaffectthevolumeofthefill DryVolumetricFilling Figure20 22FloodingorConstantStreamFiller 动画 DryVolumetricFilling 3 AugerFillersUsearotatingaugerinafunnelshapedhoppertodeliveraspecificamountofproductataconstantrate Figure20 23 Thevolumeofthefillisdeterminedbytheextentoftherotationmadebytheauger Someaugerfillershavetimingmechanismsthatallowtheaugertoturnforapresettimeoneachfill andotherdesignscountthenumberofrotationsthattheaugermakesoneachfill DryVolumetricFilling Figure20 23Augerfiller DryVolumetricFilling Usedforawidevarietyofproducts buttheyareparticularlyappropriateforproductsthattendtobridgeovertheopenings suchasfinelygroundcoffee cakemixes andflour TheaugershowninFigure20 24isusedtomovenonfree flowingpowders andtheaugershowninFigure20 25isdesignedtoprovideanevenflowoffree flowingpowderswhilepreventingthenaturalflowwhentheaugerisnotturning DryVolumetricFilling Figure20 24Augerfornonfree flowingpowder Figure20 25Augerforfree flowingpowder 动画 DryVolumetricFilling 4 VacuumFillersSimilartothefill to a leveloperationsusedwithliquidproducts Figure20 26 Theyusethecontainerasameasureofthefill Avacuumisusedtodrawoffexcessproductandtotamptheproductforatightfillorpreventingproductdustfromescapingintotheair DryVolumetricFilling Figure20 26Vacuumfillersfordryproducts DryFillingByWeight IntroductionForsomeproductstheweightoftheproductineachpackageismoreimportanttotheuserthanthevolume andthecostoftheproductmaymakeituneconomicaltodeliberatelyoverfillsomeofthecontainersinordertoguaranteethattheyallcontainaminimumweight Therearetwobasictechniquesforfillingbyweight netweightandgrossweightfillingsystems DryFillingByWeight 1 NetWeightFillingBeingthemostaccurateofthefillingtechniques Eachproductloadisweighedseparatelyinthefillingmachinebeforeitisloadedintothecontainer Fig 20 27 Easilyusedforfilingbagsandotherflexiblecontainersthatmustbesupportedduringthefillingopera