What Is A Tube Filling Machine?
A tube filling machine is designed to fill containers. The machine automates all or part of the process, simplifying it.
These machines are usually integrated into the production line. The best quality machines can be programmed and will accurately fill each container with a set, pre-defined, amount of material. Every machine has a control panel allowing you to determine, speed, fill levels, consistency, and many other functions.
Essential Parts Of Tube Filling Machines
Every tube filling machine should have the following components:
Safety System
An emergency stop button to turn the machine off instantly in case of issues. In addition, it should have a series of alarms to warn of issues.
Frame
The outer shell of the machine which holds it all together.
Hopper
This funnel-shaped section stores the product before it is distributed into the tubes.
Tank
This sits before the hopper and can hold a large amount of product, allowing it to be fed into the hopper as required.
Filling Nozzle
Filling nozzles come in a variety of sizes, allowing the fastest and most accurate filling of the tubes.
Coding Jaws
Coding jaws are designed to print information on the tubes. They are an essential part of creating the finished product.
Dosing Pump
This works with sensors to control the amount of product placed into each tube.
Sensors
Sensors tell the machine when a tube is in position and when it’s filled.
Control Unit
The control unit assimilates all the data to ensure the smooth operation of the machine.
Tube Holder
Every tube needs to be held prior to, during, and after filling. That’s what the tube holders do.
Motor
Tube filling machines generally have electric motors. These turn all the critical parts allowing the machines to work. The bigger the machine, the more powerful the motor.
Tail Cutter
Designed to trim the tail after filling, ensuring every product looks perfect.
Sealer
Automatically seals the tube after filling is complete to maintain quality and longevity.
Packaging Device
Similar to the hopper but usually upside down. It guides the filled and finished tubes into boxes, or wherever else you would like them to go.
Types Of Tube Filling Machines
There are several types of tube filling machines. Understanding the differences is critical if you want to purchase the right machine for your business.
Your decision will be based on the budget you have available, how much space you currently have, and what production levels you have or want to have.
There are three main types of machines:
Rotary Machine
Rotary machines are popular in many industries because they are flexible, practical, and come in both fully and semi-automatic options.
This type of tube filler has a heavy base and allows you to fill, seal, crimp, code, and pack in one transaction. Importantly, the rotary tube filling machine uses hot air to seal the tubes. This is considered the very best option as the tube is warmed, and can be easily bent and shaped. It’s then welded shut with specialized jaws.
Semi-Automatic Machines
As the name suggests, a semi-automatic tube filling machine automates parts of the process but you’ll need an operator to handle some of the stages.
For example, semi-automatic fillers will generally fill the tubes, but they won’t slide them into position or package them afterward. An operator needs to ensure the tubes move smoothly through the process, assisting where necessary.
Some semi-automatic machines need an operator to start the machine and collect the filled tubes, nothing else.
This type of machine can produce between 30-35 tubes per minute, making it the perfect option for smaller-scale productions and start-ups.
Naturally, it’s smaller than a fully automatic machine, making it a good option where space is limited. They are easy to operate.
Fully-Automatic Machines
This type of filling machine does everything for you. It’s necessary to program the machine via the control panel. This tells it how much product should be in each tube, what information should be printed on it, and several other critical details.
An operator needs to ensure the tanks supplying the material and the tubes are full. Once started, the machine will keep going until these tanks are empty.
These machines have a high production rate but are much larger than semi-automatic versions. It makes them a good option for large-scale productions, well-established businesses, and those with plenty of space.
Although you’ll need a larger budget to purchase a fully automatic tube filling machine, the ongoing costs are less, making it a sound investment.
Benefits Of Tube Filling Machines
Regardless of which tube-filling machine you choose, you’ll find that there are several benefits to using them.
Multiple Applications
Tube filling machines can be used with a wide variety of materials. While you may need to change the filler nozzle and reset the control panel, the machine can easily switch between filling toothpaste tubes to filling a tube of anti-bacterial cream or even a prescription gel.
Multiple applications make these machines a worthwhile investment, the range of products you can put in a tube is almost limitless.
Naturally, it’s a good idea to consider your product first, particularly the viscosity and denseness of the product. It can affect your choice of machine.
Cost Saving
Trying to fill tubes manually is a slow process. It requires a lot of people and you’ll need almost as many people to perform quality checks and ensure every tube has the same amount of material and is packaged properly.
Tube filling machines eliminate this issue. Because they handle everything for you they can not only fill tubes faster, you’ll need considerably fewer staff numbers.
That’s great for productivity, efficiency, quality, and your bottom line.
Ensures Quality
A semi or fully automated machine will fill every tube with the same amount of product and, if necessary, mix the products in exactly the same way.
In other words, you’re guaranteed every tube is the same, which means the quality of your product remains the same.
Quality is important. It helps to ensure the product is effective and, it ensures you have a positive brand reputation. Both of these are vital for your ongoing success.
Less Wastage
Machines automate the amount of product going into each tube. There is no overfilling and much less wastage than when tubes are manually filled.
You’ll use less product which lowers your production costs. You’ll also be reducing any environmental impact from your business; that’s good for the environment and your reputation.
Hygenic
Tube filling machines are generally made of stainless steel. This makes them easy to clean and decreases the likelihood of bacteria living on the surface. The best tube filling machines are easy to clean.
Hygienic machines ensure the quality of your product and your reputation.
Brand Uniformity
Using a machine means that your tubes of product are finished and sealed in the same way. The information printed on them is in exactly the same place and your logo will be clearly visible.
Uniform products show buyers that you are a serious business. It encourages confidence in your brand which promotes loyalty.
In short, the right tube filling machine can help you beat the competition.
Industries That Use Tube Filling Machines
These machines can be used in almost every industry.
Pharmaceutical
The pharmaceutical applications are broad, from tubes of pain-relieving gel to muscle relieving, and even ointments and pastes to fight bacteria.
If your product can be distributed in tubes, the tube filling machine is the right investment for you.
Hygiene
Shampoos, soaps, creams, and a host of other beauty, cleansing, and cosmetic products come in tubes.
It’s fair to say almost every product in the hygiene and cosmetic industry is inside a tube. In short, if you’re operating in this industry you can’t afford not to have a tube filling machine.
Food Products
The food industry is passionate about tubed food products. From cheese in a tube to a multivitamin paste, tubes are everywhere in this industry.
In fact, putting your food in a tube can be a great way to stand out from the competition. It helps that tubes are easy to carry with you and can be eaten while on the move.
Pet Goods
Pet medications are often packaged in tubes as this makes it easier to administer the correct dose.
It’s also common for the pet industry to store treats in tubes. Again, this makes it easier for the administration of those treats to a pet.
Stationery
Paints, particularly watercolors and oil-based paints, generally come in tubes. A tube filling machine makes it easy to create the product, attracting customers to your business.
It’s not just paint, you can purchase glue in tubes, alongside glitter and other decorative products.