I know you are probably looking for highly efficient and reliable aluminum tube filling machine. A reason this guide explores all the vital aspects about aluminum tube filling machine including features, parts, working principle, and sealing mechanism, just to mention a few.
1. What Is Aluminum Tube Filling Machine?
It is an electromechanical equipment designed for filling and sealing different aluminum-material containers with semi-liquid products.
This machine feeds, orients, fills, and seals the tube using different set mechanisms hence ideal for semi-liquid products of different viscosity.
You can find it in different sizes with various capacities and operation modes.
This equipment is an excellent investment, whether for a new or existing business.
aluminum tube filling machine
Hence, this article discusses several concepts to enable you to understand different elements concerning the machine.
As such, it becomes easy to make an informed decision when the need to purchase it for your business arises.
2. Types Of Aluminum Tube Filling And Sealing Machine
Ordinarily, this equipment is available in a wide range of types.
Of course, all the available types of aluminum tube filler and sealer are designed to attain the same specific purpose.
However, the efficiency, reliability, and accuracy levels of the various types tend to contrast.
Here are the common variants you are likely to find across different applications;
Manual Tube Filling Machine
It is a type primarily that involves operating its different functional parameters by hand.
Essentially, an operator is involved in various aspects of this equipment’s operations.
Tube is loaded onto the filling nozzle, and a hand switch or button is pressed to prompt it to dispense the product.
manual tube filling machine
Furthermore, sealing and labeling of the tube are also activated manually.
Importantly, manual tube filler hardly requires a power supply to fill the tubes.
The core elements of manual tube filler include; inexpensive, user-friendly, and ideal for small-scale production and laboratories.
Semi-automatic Tube Filling Machine
It is a type of tube filler that offers manual and automatic functions.
This simply means that some operational functions of this equipment can be activated manually and others automatically.
It requires an operator but does not necessarily involve much labor compared to a manual tube filler.
The operator must load the tubes manually since it does not feature a power conveyor.
Ideally, it has pistons, syringes, or nozzles for maintaining zero drip filling.
semi automatic tube filling machine
Thus, the automated functions in this machine variant make it faster and more user-friendly.
Moreover, it is more affordable than fully automatic units and ideal for small and medium production volumes.
Fully Automatic Tube Filling Machine
This type of aluminum tube filler with 100% automated operational functions.
Almost all its functional parameters are programmed thus have little to no human involvement.
It features a human-machine interactive interface; hence easy to program and adjust the variables during filling and sealing process.
This variant is highly efficient, relatively fast, and guarantees higher production volume hence suitable for large-scale applications.
automatic tube filling machine
However, it is a bit costly to acquire and needs more in-depth routine maintenance from time to time.
3. Advantages Of Aluminum Tube Filling Machine
Ideally, packaging is a fundamental aspect in determining the sales process and returns.
Hence, it is fundamental to invest in a formidable aluminum tube filler that guarantees best results.
Some main benefits of investing in this packaging equipment include the following;
- Provides Reliability And Consistency
In a typical manufacturing setting, reliability and consistency are critical elements that define turnaround time and quality of the product.
This equipment allows you to attain a high level of reliability and uniformity, which improves the general tube filling efficiency.
- Guarantees Accuracy
Automatic and semi-automatic aluminum tube fillers ensure the product is filled to the required levels.
In essence, it averts unnecessary incidents of under-filling or over-filling, which often raises product quality issues.
- Offers Versatility
Most aluminum tube fillers are designed for filling and sealing a host of semi-liquid products in different aluminum containers.
Therefore, you can use it for filling different products into various packages, which, in the long run, makes it cost-effective.
- Reduces Product Wastage
The precision in automatic and semi-automatic aluminum tube filler prevents wastage.
It is set based on the required quantity levels to fill in the tube hence reducing cost significantly.
- Enhances Cost-Efficiency
Investing in this machine means you will eliminate the need for human labor considerably.
It also means other running costs like utility bills will be reduced and ultimately enables you to save on cost.
- Improves Employee Safety
This machine comes with different safety features that prevent the operator from any potential harm.
Furthermore, the operators hardly come in direct contact with the machine’s operations, reducing injury risks significantly.
4. Aluminum Tube Filling Machine Vs. Plastic Tube Filling Machine
Primarily, there is a thin line between aluminum and plastic tube fillers.
Aluminum tube filler is mainly designed for filling viscous semi-liquid products into different tubes made of aluminum material.
On the other hand, plastic tube filler is designed to fill thin and high viscous products in a wide range of plastic material tubes.
The working principle of these tube fillers is more or less the same since they use similar mechanisms depending on specific type of machine.
plastic tube filling machine
Also, they share more or less similar features such as filling and sealing options, as well as production speed.
Therefore, in different instances, you may use these machines interchangeably by adjusting a few settings for different variables.
5. Features To Look For In Aluminum Tube Filling Machine
Different types of aluminum tube fillers have different features based on their design and function.
Nevertheless, the most outstanding structural features you will find in this machine include the following;
- Auto-Feeding, Filling, And Sealing Systems
Automatic aluminum tube filler has an inter-connected design adopted for auto-feeding products into tubes.
This includes tube placement, filling, sealing, and ejecting.
- Sturdy Structure
The structural design of this machine features a solid structure made of stainless steel framing material.
This allows it to attain desired durability and efficiency with fast and quality functioning.
- Air Blowing Unit
The filling head contains a blowing and cutting out filling mechanism to safeguard the sealing quality and filling quantity influenced by highly viscous products.
- Effective Filling Nozzle
It has a filling nozzle that is easily extended for efficiency in filling and protecting tube sealing quality under material adhesion quality.
- Advanced Design Construction
This equipment produces a safe and clear filling process.
The major components coming in contact with product are made with hygienic and easy-to-clean materials.
- Efficient Running Formats
You can choose from a semi-automatic or fully automatic running formats depending on your application demands.
- Faster Piston Head Dispensing
Reliable piston guarantees high filling accuracy of the product, which can be easily disassembled when the need for cleaning and maintenance arises.
6. Sealing Mechanisms In Aluminum Tube Filling Machine
The quality of tube sealing is an important element for a wide range of products that are packaged using this means.
Of course, sealing methods for aluminum tubes are quite broad, but the main ones include the following;
· Hot Air Sealing
It is a comparatively straightforward process and entails feeding the tube into the equipment, where it is heated and cooled to seal the ends.
This sealing mechanism is easy and quite fast and produces a sturdy seal, able to endure unfavorable conditions like high pressures and temperatures.
Besides, it barely needs special solvents or chemicals hence eco-friendly.
· Ultrasonic Sealing
This sealing technique uses high-frequency sound waves to generate friction and heat.
The heat is, in turn, used to fuse the two different materials and ultimately creates a sturdy bond.
One main benefit of using ultrasonic sealing is its ability to generate strong bonds relatively fast.
Also, it reduces contamination risks since it is a non-contact method and averts heat damage to sensitive products.
· Impulse Sealing
This sealing mechanism uses electrical-current machines to heat and seals the end of metal tubes.
It is quite a fast and suitable choice for high-volume production.
Impulse sealing is also safe for the products and the consumer, in addition to its affordability.
· Hot Jaw Sealing
It uses hot-jaw sealing machines to heat a sealing jaw used in sealing the aluminum tube.
Technically, the machine generates heat, which melts the tube from the jaw and presses it to form a waterproof and airproof hematic seal.
The hot jaw sealing equipment is also used to form a tamper-evident seal.
7. Filling Mechanism In Aluminum Tube Filling And Sealing Machine
Aluminum tube fillers and sealers use different mechanisms to fill and seal various products into their respective tubes.
aluminum tube filling and sealing machine
The popular methods these machines use include the following;
· Piston Filling Mechanism
It is a tube filling method that uses a piston filler to fill products into the tubes.
Ordinarily, the piston filler features an in-built reservoir allowing it to hold a measured quantity of the product.
The filling nozzle is dipped into the aluminum tube, and its pistons on the other end push the product to fill the tube.
More products are measured into the reservoir to be dispensed into the subsequent tubes.
· Vacuum Filling Mechanism
This mechanism uses a vacuum system equipped with a vacuum pneumatic pump that forms a depression inside the tube.
Tube filling only takes place after depression phase.
The negative pressure formed sucks the product from machine’s hopper into the tube until it gets to its desired fill level.
Upon realization of the pre-set level, the excess product level is collected in a recovery tank and re-sent to the processing system before filling.
· Gravity Filler Mechanism
It is a straightforward tube filling mechanism that involves placing the product above the filling station.
Essentially, this method depends on gravity to draw the product from the hopper into the tube.
· Volumetric Filler Mechanism
This technique utilizes a volumetric pump to draw the product from hopper into the tube.
It dispenses a uniform product quantity into a tube using a time-based system, which halts the filling after a set period.
A specific product volume is filled out within the allocated timeframe to create consistency.
8. Parts Of Aluminum Tube Filler
The main parts of this machine include the following;
- Tank – It is a chamber used for holding products required to be filled up.
- Frame – Made from a robust material, it is the component supporting all other parts within the machine.
- Hopper – This is a device resembling a funnel designed for transferring products from a receptacle to other units.
- Filling nozzle – It is the unit used for regulating fluid flow into the aluminum tube.
- Tube holders – They are designed to grip the tubes before, during, and after filling.
- Tube container – It is used for storing empty tubes before filling.
- Dosing pump – It is designed to accurately fill the fluid into the tube based on the set quantity.
- Cooling unit – This part is used for cooling the tubes to offer good sealing effects.
- PLC control unit – It contains different components used in regulating various parameters of product filling.
- Discharge unit – This device ejects a filled and sealed tubes after treatment through a chute.
- Sensor – It detects tube and fills product into the tube
9. Working Principle Of Aluminum Tube Filling And Sealing Machine
The first element of working principle of this machine involves inserting the aluminum tubes into the tube holder.
It can be a manual or automatic process depending on the type of aluminum tube filler and sealer you are using.
Essentially, the tube holders rotate with the rotary table hence positioning them at various workstations.
At this point, all parameters are already set from the PLC control unit.
Thus, the machine conducts all the respective operations in an arranged sequence.
The process starts by filing, sealing, placing batch number, and cutting off the tail.
All these functions are automatically activated.
At completion stage, the functions will be at different intervals on particular workstations.
Notably, the entire process of this equipment allows you to adjust the filling quantity and speed easily.
10. Applications Of Aluminum Tube Filling Machine
This equipment is increasingly used in different modern industries, and the common ones include the following;
- Pharmaceutical industry
- Hygiene industry
- Food processing industry
- Pet food manufacturing industry
- Cosmetic industry
- Stationary industry
11. Aluminum Tube Filling And Sealing Machine Maintenance Process
Maintaining this machine enhances its efficiency, performance, and longevity.
Here are some typical maintenance processes to undertake on this particular machine;
- Frequent cleaning
Ensure you clean the machine thoroughly, including its nozzles, tubing, and seals, to prevent residue buildup and ensure the equipment is always ready.
However, make sure to cut off power before starting the cleaning process.
- Regular checkups and servicing
Carry out regular checks on the machine by inspecting the parts to determine tear and wear and ensuring seals are intact.
Also, lubricate all the moving parts to reduce friction and ensure parts give a longer service lifespan.
- Conduct software diagnosis
Ensure you scan the equipment on a computerized system to diagnose and establish any possible software concerns and upgrades.
It enhances efficiency of the machine and guarantees reliability in the long run.
12. Troubleshooting Aluminum Tube Filling Machine
Occasionally, you may encounter a few functional or mechanical issues when using aluminum tube filler and sealer.
However, most of these issues are easy to troubleshoot without necessarily involving a technician.
Here is how to troubleshoot some problems arising from this machine;
- Failure Of Machine To Start
Often arise due to electric power interference, zero air pressure, or when an emergency button is pressed.
To solve it, power the machine on and check the fuse.
Also, check the connection between the equipment and PLC communication.
- Inaccurate Product Filling Volume
Likely to arise from impurities in the product, which in turn, produces foam. Solve this by cleaning the filling pipe of the product filter.
It may also arise from plate breakdown or interruption of an electromagnetic valve; thus, you need to replace or clean them respectively.
- Heating Spray Bottom Contacting The Product
It occurs due to excess material filled in the tube; thus, you need to adjust filling blowing to stop the product spattering.
- Incorrect Tube Labeling
Usually occur due to misaligned labeler or inaccurate settings; hence you need to check whether labeler is placed correctly and the settings are accurate.
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