Have you noticed technical issues in your beverage production lines recently? This can be due to various factors that affect your filling machines performance from incorrect filling volume to over leakage of liquids. You must know how to identify the scope of the problem early on so that engineers can work towards a clear solution. 

These are the 6 common filling machine problems and solutions to help your operations run smoothly again:

6 Common Filling Machine Problems and Solutions

1. Power Issues 

If you have noticed that the power indicator is off or that it repeatedly turns on and shuts down, then there must be a problem with the power connection. It is possible that one of the wires or the connector to the power switch is damaged. 

SOLUTION:

• Unplug the machine for a time and then plug it back in. 
• Assess any wire damages, then repair while the machine is off.
• Replace power switch. 
• Check your conveyor belt if there were any lodged materials that could cause an emergency shutdown. 

2. Filling Volume 

Does the machine put the wrong amount of fluids inside the packaging? If so there must be a problem with the filter or filling nozzle. There could also be more technical issues with the machine’s software calibration or internal valve components. 

SOLUTION:

• Inspect if there are any air leaks on clamps or hoses, then replace damaged seals.
• Examine if any of the nozzles or filters are blocked then clean both thoroughly. 
• Check your settings and recalibrate the machine to have optimal liquid fills. 

3. Bottle Transport

You might be experiencing issues with how your bottles are moved and placed. This inconsistency in spacing can be the cause of a problem in your conveyor belt or incorrect placement of bottles into the machine. 

SOLUTION:

• Adjust the movement speed and tension of your conveyor belt.

4. Bottle Tipping 

The problem of bottle spillage is a common filling machine issue caused by the unsteadiness of the conveyor belt or improper bottle placement. This can lead to wastage of materials and further damage to your bottle-filling machines. 

SOLUTION:

• Modify your conveyor belt operations to be more precise.
• Adequately train your staff to place the bottles correctly to be processed. 

5. Start-Up Trouble

This is often characterized by the machine having various malfunctions in pistons or valves. This can be caused by low air pressure which makes it unable to provide the necessary support to operate properly.

SOLUTION:

• Assess if your air compressor provides the right amount needed for your valves and pistons to function. 

6. Supply Problem 

It’s possible that turning off the supply hold of liquid for your automatic filling machines can cause inconsistent fills. If the main supply of liquid is low, then a resupply while the machine is still operating can affect the amount poured into your bottles.  

SOLUTION:

• Consult with experts on how to adjust your supply levels so that there is no excess filling. 

Solutions for Your Filling Machine Operations

Regular maintenance and inspections are crucial for preventing these issues from recurring. Consider implementing a preventive maintenance schedule to prolong the life of your filling machines. For more complex problems, consult with an expert to properly manage filling machine problems and solutions. Address these challenges proactively to significantly improve your production efficiency and product quality.

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Elixir Industrial Equipment offers technical support services to ensure that your production lines operate efficiently and avoid any future issues. Get in touch with our experts to optimize and maintain your bottle filling machines for your business.