Ointment Filling Machine: The Ultimate Guide

In this guide, you will find all information about ointment filling machine. From filling mechanisms, sealing technique, features to working principle – this guide explores everything on ointment filling machine. Let’s dive right in.

1. What Is Ointment Filling Machine?

It is a machine that is used to fill products such as toothpaste, cream, lotion ointment into a plastic tube hence it is designed with sealing and filling process.

The filling machine differs depending on the product since most of them are measured in prescribed quantity.

ointment filling machine

ointment filling machine

We have various types of filling machine corresponding to paste, granular materials, powder or liquid.

2. Industries Using Ointment Filling Machine

The filling machine can be used in different industries where the products are kept and delivered in tube form.

They use specific techniques to seal the tubes thus to prevent the products in the tubes from spilling off hence some are heated before sealing while some they use fold and cramp technique.

It is used for packaging highly viscous liquids or pastes.

It is commonly used in the following industries;

  • Cosmetic industry is used for packaging of gels and creams.
  • Food industry for packaging of food paste.
  • Pharmaceutical industry for packaging of toothpaste and ointment.
  • Chemical industry for packaging of glues and sealants.

3. Why Invest In Ointment Filling Machine

Ointment filling machine cut costs hence they contribute greatly to the production in many industries.

The advantages of these machines in your business are;

Higher Production Speeds.

When the machine is automatic, it allows you to produce as many products as possible compared to hand filling.

The machine can speed up to 200 tubes per minute hence allowing as much tubes to be filled per day.

The production efficiency increases due to its rapid speed hence it’s an advantage in filling up products like creams and lotions in tubes quickly.

Lower Operation Interruptions

The company decreases the production cost and the machine deducts the labour workload as well as the easy operative feature hence you can access the machine easily.

The machine requires very simple hand adjustments to change from one tube to another but the complex settings such as indexing times and speeds are set on touchscreen interface.

Scalable.

Filling machine can be upgraded without changing the gadget hence it only depends on the model maximum business filling machines which may begin with 6 to 8 filling heads.

It reduces the wastage of products as the leftovers of the product are collected by the machine and is used in another tube.

Consistency.

Using manual work force will definitely cause inconsistencies in terms of the quantity of the product that is going inside to be filled.

The machine must be of heavy-duty stainless-steel frame hence to prevent shifting, vibrating and other movement that might affect the volume of the fill.

The stainless-steel material is compatible with majority of products hence when corrosive liquid is run on the machine, other materials can be used like HDPE.

The life of the equipment is determined by the type of the material used to make it.

Filling Versatility.

It can fill any form of product in any desired measurement when correctly adjusted during the settings whether thick or skinny liquids.

4. Dosing Techniques In Ointment Filling And Sealing Machine

The following are the dosing techniques in ointment filling and sealing machine;

Gravity Filling.

The technique ensures there is no air introduced and to guarantee a very low level of dissolved oxygen in the product.

It is the simplest filling technique hence the filling stem are attached to the bottom surface of the bowl at each container filling point.

Gravity filling allows the gravity to draw the liquid down the bottled thus operates by storing the liquid above the bottles to be filled.

Piston Filling.

Commonly used for viscous products that are thick with large particles but can also process semi-solids.

They pump products into containers in desired amounts and once fully retracted, the piston will return to the cylinder, forcing product into the supply line leading to the fill heads.

It is suitable for higher-cost liquids that need to be dispensed in various amounts with little waste or no wastage at all like pharmaceuticals.

Volumetric Filling.

It depends on a positive displacement piston pump with a specific volume hence it’s a technique of depositing a given volume of product accurately.

The piston pump can handle thick products like cream and pastes hence it does not depend on outer pumps or gravity to produce a flow.

Vacuum Filling.

Air in the bottle is pulled out by vacuum pump when the filling nozzle is inserted into an empty bottle and the sealer is sealed.

The filling nozzle bypasses the product into the collection tank when the bottle is full and reaches the pre-set filling level.

The products are filled without any contact between product and the pumps hence they are transferred back to storage tank.

There two types of vacuum filling machines; rotary and Linear.

Pump Filling.

This method is known to work best with products like honey or car wax since it can move thickest products.

It is convenient for one operator who wants to fill containers of different sizes since it allows you to change between different fill volumes.

5. Sealing Mechanisms In Ointment Filling And Sealing Machines

Here are the sealing mechanisms in ointment filling and sealing machines.;

Ultrasonic Sealing Method.

The method generate heat at a molecular level using vibrations which are created with sonotrode and anvil.

The vibrations make the molecules in the liquid to start moving and the plastic becomes soft and starts melting hence the components are then bonded by cohesive.

No direct heat on the material is required since the molecular friction allows the material to seal.

Hot Jaw Sealing.

The method is usually used where the material is melted to seal it and left to cool down hence to set before the jaws of the machine are opened.

A constant heat sealer is used when sealing laminate type materials thus allowing the jaws of the machine to be set constantly at the correct temperature to seal the internal layers.

It is a quicker method compared to other method but it cannot be used on polyethene.

Impulse Sealing Mechanism.

The sealing bar is pressed closed and pushed on the wire and film to melt thus to mend the material forming a seal.

An electrical current is sent to the end connector posts when the sealing bar is closed thus the end posts heat the sealing wire with the electrical current.

The method can be used with foil, polycoated kraft paper bags and other plastic materials

Hot Air Sealing Mechanism.

This method involves the use of a nozzle to force heated air between two layers of material hence the desired seam width is lapped at the nozzles ae the two panels are fed through metal folders.

The materials are heated and melted slightly before going through the pressure rollers thus after the pressure rollers weld the materials, the product is then cooled.

It allows the flexibility in how the material moves through the metal folder and pressure holders.

6. Parts Of Ointments Filling Machine

Frame.

Not all projects will require automatic production so portable frames can be rolled up to an existing conveyor line and put into production.

Other frames can be used to create standalone filling stations, using a slide track rather than a power conveyor and requiring the operator to place and remove bottles.

The frame used will change with the requirements of the packaging process hence standard portable frames will be used for most automatic machines.

Product Pathway And Nozzles.

The pathway is like plumbing, tubes and nozzles hence they are used to get the products from the holding tank to the waiting bottles and containers.

The material used for plumbing and tubing may change to meet the needs of the product thus they may change to avoid undue wear and tear from a product.

Nozzle sizes may change depending on the size of the containers or container opening hence the material may be chosen to complement the product while not creating wear and tear.

Tanks.

Tanks are used for product returning from the overflow nozzles thus different filling machine uses different thanks at different locations.

The tank size, material and location will depend on the product, production demands and fill principle.

However, gravity filling machines will use a product supply tank that will rest over the top of the nozzles while other filling machines may or may not use tanks.

  • The motor capacity, discharge unit or the dosing pump and the coding jaws are also some parts of the tube filler.

7. How Ointment Filling And Sealing Machines Work

We have two processes used for the production of ointment such as cream, lotion, paste or gel.

Some of the key steps include:

  • The first step is called the water phase since it is done in a container known as the water phase vessel and similarly the wax and oil are mixed in another wax phase vessel.
  • The both containers are heated and mixed with the help of motor driven agitators and then filtered and moved to another container through pipes by vacuum system.
  • The mixture is heated and stirred while adding a drug in it with a high speed for homogenization and emulsification of the mixture to distribute the components uniformly.
  • A pump is used to transfer the product to the storage tank where there is heating and moving wheels and moved to the filling machine and heated for east transportation.
  • A metering pump transfer the product to the hopper of the filling machine then triple roller is used to move the extra water from the final product before filling it into the tubes.
  • The tubes are loaded into the filling machine where the piston sends out the calculated amount of the ointment that goes through a nozzle into the tube.
  • The tube is the passed through the pressing station, crimping station and coding station hence in the case of plastic tubes, they undergo through air blowing station.
  • After the product is ejected out from the filling machine, they are sealed and trimmed and the systems automatically wash all the containers used in the processes.
  • Our ointment tubes are ready to rock in the market.

8. Features To Look For In Ointment Filling Machine

The following are the features of a good ointment filling machine;

Easy To Operate.

The machine should have simple adjustments to minimize downtime and maximum production.

It requires very simple hand adjustments to change from one tube to another but the complex settings such as indexing times and speeds are set on touchscreen interface.

However, fill heads can be moved with adjustments knobs and power height comes on automatic equipment.

This allows up and down movement with a flip of a switch.

Adjustments such as time and delay settings can be made from the operator control panel.

Consistent Functioning.

The machine must be of heavy-duty stainless-steel frame hence to prevent shifting, vibrating and other movement that might affect the volume of the fill.

The stainless-steel material is compatible with majority of products hence when corrosive liquid is run on the machine, other materials can be used like HDPE.

The life of the equipment is determined by the type of the material used to make it.

The Filling Accuracy Rate Is High.

It can fill any form of product in any desired measurement when correctly adjusted during the settings whether thick or skinny liquids.

The machine can be able to handle filling of different kinds of liquids like water, oil, cleaning fluids and automotive fluids thus it is designed to satisfy its users.

Prepared As Per Quality Standard.

It improves the product output, quality and effectively save costs thus provide maximum profits to the company and its users.

Filling Volume And Filling Speed Can Be Adjusted As Required.

When the machine is automatic, it allows you to produce as many products as possible compared to hand filling.

The machine can speed up to 200 tubes per minute hence allowing as much tubes to be filled per day.

Sturdy Design.

The stainless-steel material is compatible with majority of products hence when corrosive liquid is run on the machine, other materials can be used like HDPE.

9. Ointment Filling And Sealing Machine Maintenance Process

To avoid damage of the machine, it must be kept clean and the tool should be used properly hence you should avoid to use excessive force to remove the parts.

It is strictly forbidden to have liquid, glass debris or oil on the machine thus the machine removes the glass debris in time during the production process.

All the activity departments are cleaned and clean lubricating oil is added before the delivery hence they are scrubbed once a week.

During disinfection, loosen the upper and lower set screws and remove the liquid injection system hence put the inlet tube in the cleaning solution to start cleaning.

Use type 10 with standard 5ml or 10 ml syringe for filling machine, type 100 with 100ml for glass filler when measuring disinfectant.

ointment filling and sealing machine

ointment filling and sealing machine

Wipe it with alcohol or oil to keep the stainless-steel body smooth and clean hence do not scrape its surface with sharp object.

Check whether the random technical data is complete and also check if the machine is damaged during transportation after the machine is unpacked.

Install discharging assembly and adjust the feeding assembly according to the outline drawing in the manual hence add new lubricant to each lubrication point.

However, the machine should be lubricated before leaving the company thus you should not open the cylinder or add any lubricating oil.

The seal rings on the discharge piston and the lower end of the discharge cylinder of the liquid filling machine should be replace in time after they are worn out.

The machine must be protected from the grounding thus you should rotate it with the rocker to check if it is running in the right direction.

10. Troubleshooting Ointment Filling And Sealing Machine.

There are many types of problems that can affect your filling machine hence if you want to keep it in good shape, there are some malfunctions to look out for like;

Power Problems.

Power surges can be particularly detrimental for your production line hence causing a complete breakdown that can cause loss of productivity or product damage.

Avoid costly breakdowns by ensuring you have a backup generator and enough power to handle each piece of the equipment you introduce in your filling machine line.

Dripping And Foaming.

Dripping and foaming always waste liquids dues to inadequate sealing hence causing loss of product over time.

This problem can be solved by tightening seals and making sure that valves don’t leak during and if the seal is irreparable, make sure you replace the entire filling machine.

Use diving nozzle in foaming issues hence the diving nozzle usually reaches the bottom of the container during the filling process.

Perform Regular Preventative Maintenance Checks.

To avoid losing money and causing damage to your filling machine, develop a maintenance schedule that works.

Make sure you check your machine for defective or malfunctioning parts on a regular basis thus to avoid this kind of problem.

Consult a company expert to help you monitor your machine if you are not sure about which parts of your filling assembly needs help.

Inaccurate Filling Level And Timing.

This problem is usually caused by overflowing and wasted product or inadequate filling of containers hence causing a surplus of product.

Check for wear and tear on seals which may need replacement if tightening them doesn’t work and check parts that allows air into the product pathways.

Inaccurate timing can also cause this problem hence make sure you change operational settings rather than adjusting equipment hardware.

11. Types Of Tubes For Filling Ointment

Squeezable tubes are very flexible to hold and dispense a wide rage of products along with being easier and less expensive to make, fill and cap over other containers.

Most company use the tubes for ointment because they have increased resistance to breaking, good durability, air tightness and longer product self-life.

Here are examples of tubes used for filling ointment;

Plastic Tube

They are light-weight, durable, leak proof and non-breakable thus they protect the product contained in them hence to extend the products self-life.

The tube usually returns to its original shape when squeezed without distorting any of the printing hence it can be finished and decorated in many various ways.

plastic tube

plastic tube

Plastic tubes can be used in products like, shampoos, tanning lotions, facial mask, hand creams and cleansing creams.

Laminated Tube

These tubes were used primarily to package toothpaste but today, they are for many other various products like, medical ointment, oral care product and paints

They are of low cost, durable and more flexible hence they are constructed with different layers of aluminium and plastic providing a good barrier inside the tube.

The materials provide the packaged product enough protection from oxygen and allows the tube durable hence keeping its outer appearance attractive.

laminated tube

laminated tube

There are two types of laminated tubes;

  • ABL (aluminium barrier laminate)
  • PBL (plastic barrier laminate)

Aluminum Tube

The tube provides a superior protection to its contents hence it is made of multiple thin layers of 99% pure aluminium.

An interior lacquering prevents the product from reacting with the aluminium and the sealing end of aluminium is lined with latex to avoid leakage of the product.

We have many types of options for aluminium tubes hence they are seamless and are good at keeping products like pharmaceuticals fresh.

 aluminum ointment

aluminum tube

Aluminium tube can be shoulder coated, open, long or closed nozzle, base coated plus 4- colour printing and custom cups of any shape, size and colour.

12. Types Of Ointment Filling Machines

The different types of machines provide their unique performance and efficiency hence the machine you choose will depend on factors like bottle shape, size and the product itself.

The following are the types of ointment filling machines;

Fully Automatic Ointment Filling Machine.

It’s the best machine if you need a mechanism that is fully labour free thus has minimal human interaction.

It features ensures fewer adjustments which saves time and offers utmost safety thus it offers a fill with a shut-off nozzle which enhances the cleanliness in filling.

 automatic ointment filling machine

automatic ointment filling machine

The operational cost of the machine is very low hence all its functionalities are programmed which makes it good for large-scale production.

Manual Ointment Filling Machine.

The machines are suitable for filling wide range of products from free-flowing liquids such as perfumes and spirits hence they require no power source.

They can be used in environments where there is no electricity or compressed air is not available hence, they are hand operated.

manual ointment filling machine

manual ointment filling machine

They are ideal for small scale production or in areas where external power source is not reliable like laboratories.

Semi-automatic Filling Machine.

This machine can be used if you need to supplement your fully automatic machine hence it is easy to use and it comes with different designs, shapes and capacities.

 semi automatic filling machine

semi automatic filling machine

They come in small sizes but ensure smooth functioning in event of any failure of the main machine hence the apt for small to medium scale production.

Related Resources:

Tube Fillers

Cosmetic Tube Filling Machine

Toothpaste Filling Machine

Cream Tube Filling Machine

Automatic Tube Filling Machine

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