Let’s see how filling solutions for dense and semi-dense products work, and what advantages automated systems bring.
Efficiency in production processes is key to ensuring the profitability and competitiveness of any industry. One of the most critical aspects in sectors such as food, cosmetics, chemicals and pharmaceuticals is the filling of dense or semi-dense products, where precision, hygiene and production speed play a fundamental role.
Manual or poorly automated systems can lead to dosing errors, raw material waste and longer production times. Therefore, many companies opt for automatic or semi-automatic fillers, depending on their production volume, accuracy needs and desired degree of automation.
Sectors requiring filling systems for dense and semi-dense products
Dense and semi-dense products have characteristics that make them difficult to handle, as they do not flow as easily as liquids, but neither are they completely solid. These filling systems are essential in industries such as:
- Food: Sauces, jams, honey, yogurts, spreadable creams, ice cream, liquid chocolate, liquid masses, thick dressings, etc.
- Cosmetics: Facial and body creams, gels, shampoos, lotions, balms, hair masks, sunscreens, waxes, etc.
- Chemicals: Paints, adhesives, detergents, oils, industrial waxes, silicones, lubricating pastes, high viscosity cleaning products, etc.
- Pharmaceuticals: Syrups, topical gels, dermatological products, ointments, etc.
In all these sectors, the choice between a semi-automatic or automatic filler will depend on several factors, such as the volume of production, the variety of products and containers to be used, and the need for dosing accuracy, which are compared in the following table:
| Feature | Automatic Fillers | Semiautomatic Fillers |
|---|---|---|
| Production level | High (industrial lines with high demand) | Medium-low (more flexible or batch production) |
| Operator intervention | Minimal (fully automated process) | Medium (requires supervision and manual operation) |
| Dosing accuracy | Very high (sensors and PLC control) | High, but depends on manual operation |
| Format change | Fast and optimized for different references | More manual, requires more frequent adjustments |
| Initial investment | Higher, but can be amortized over large volumes | More affordable, ideal for small and medium-sized companies |
| Maintenance and cleaning | Automated on some models | May require further manual intervention |
| Ideal for | Industries with high production volumes and automated lines | Industries with medium productions or variable batches |
How to choose the best option according to production volume?
The choice between an automatic or semi-automatic filler will depend on the scale of production and the operational needs of each company.
- For small and medium productions: A semi-automatic filler is the best choice if the production volume is below 5,000 units per day. They are ideal for companies working with customized batches or looking for flexibility in format changeover.
- For large productions: When demand exceeds 10,000 units per day, an automatic filler is the best investment. It reduces manual intervention, minimizes errors and optimizes operational efficiency.
What are dense and semi-dense products and what are the challenges of filling them?
Filling dense and semi-dense products presents specific challenges due to their viscosity and dispensing behavior. These products may flow with difficulty, require specific pumping systems or even need temperature control to ensure efficient and accurate filling.
These are the most frequent challenges in filling dense and semi-dense products:
- High viscosity and flow resistance: Dense products require powerful pumping systems and adapted nozzles for clog-free dosing.
- Precise dosing control: It is essential to avoid overfilling or underfilling, which can lead to economic losses or quality control problems.
- Avoid formation of bubbles or foam: In products such as creams and adhesives, improper filling can generate trapped air, affecting product quality.
- Drip and waste prevention: Systems should be equipped with anti-drip valves and pressure control to prevent spills.
- Hygiene and ease of cleaning: For this purpose, it is essential to have systems that can be easily disassembled or cleaned in place (CIP) without the need for disassembly.
- Adaptability to different formats: Most plants work with multiple containers and sizes, which requires flexibility in the filling system to adapt to all formats.
Key technologies in automatic and semi-automatic filling systems for dense and semi-dense products
To ensure accurate and efficient filling, filling machines for dense and semi-dense products incorporate different technologies adapted to the needs of each industry.
1. Dosing pumps for dense and semi-dense products
The type of pump used is key to ensure a uniform flow of the product without generating clogging or variations in dosage. Some of the most commonly used pumps include:
- Piston pumps: Ideal for medium and high viscosity products, such as creams, sauces and adhesives. They allow a precise and homogeneous dosing.
- Lobe pumps: Suitable for dense products with particles in suspension, such as purees with fruit pieces or cosmetic products with exfoliants.
- Progressive cavity pumps: Recommended for extremely viscous products or those with high shear sensitivity, such as industrial adhesives and silicones.
- Peristaltic pumps: Used in the pharmaceutical and cosmetic industry to avoid contamination and guarantee precision without altering the structure of the product.
2. Specialized anti-drip valve systems and filling nozzles
One of the most common problems in filling dense and semi-dense products is the formation of residues or drips after dosing. To avoid this, filling systems include:
- Mechanical shut-off valves: prevent the product from continuing to flow after filling, ensuring accurate dosing.
- Reverse suction systems: Remove excess product at the nozzle to avoid drips and residues.
- Submersible nozzles: Allow filling from the bottom of the container, avoiding the formation of foam or bubbles in products such as creams and gels.
3. Automation and volume control
Automatic and semi-automatic fillers use different control systems to ensure accuracy in each dosage.
- Level sensors and flow meters: They allow a precise control of the filled volume in each container.
- PLC (Programmable Logic Controller) control: Automatically adjusts parameters such as pressure, filling speed and dosing time according to the type of product.
- Touch screens with programmable recipes: Allow you to quickly switch between different product formats and adjust settings without complex manual intervention.
4. Materials and hygienic design
The design of the filling equipment is key to ensure durability, ease of cleaning and regulatory compliance.
- AISI 316 stainless steel: Ideal for food, cosmetic and pharmaceutical products, as it is corrosion resistant and easy to clean.
- CIP (Cleaning in Place) systems: Allow automatic cleaning of the equipment without disassembling it, reducing downtime.
- Sanitary connections without dead zones: They prevent the accumulation of residues and facilitate the complete cleaning of the system.
MarCoPack solutions for automatic filling of dense and semi-dense products
Marcopack’ s automatic and semi-automatic fillers are designed to offer efficient solutions for the packaging of liquid, semi-viscous and dense products, adapting to different sectors such as food, cosmetics, chemical and pharmaceutical industries.
The following are the models available and the main features they offer:
Semiautomatic Fillers
1.SV Filler
- Designed for filling liquids and semi-liquids up to 5l.
- It works by means of a volumetric piston dosing system.
- Suitable for small productions or formats that require manual precision.
- Compatible with different types of containers and products of various viscosities.
2. SVP Filler
- Advanced version of the SV with increased capacity and customization options.
- Rotary table for manual container feeding and removal.
- It uses a piston pump dosing system.
- Allows easy adjustment of filling speed and volume.
- Suitable for products of different densities and for industries with specific requirements.
Automatic Filler
3.Industrial Filler MCP 4000
- Fully automated system for filling liquid, semi-dense and dense products.
- It includes several dosing pump options depending on the product:
- Piston pump, ideal for viscous products such as creams or sauces.
- Lobe pump, recommended for delicate or particulate products.
- Peristaltic pump, suitable for products requiring high hygiene.
- Designed for integration into automated production lines.
- Able to work with different types of packaging and formats.
- Digital control system for accurate and repeatable dosing.
How to choose the right filling system for your industry
The choice between an automatic or semi-automatic filler for dense and semi-dense products will depend on several key factors:
- Production volume: For less than 5,000 units per day, a semi-automatic filler may be sufficient. For productions above 10,000 units per day, an automatic filler is recommended.
- Product type: Extremely viscous or sticky products require progressive cavity pumps or pressure controlled systems.
- Accuracy and control: If the product requires accurate dosing, machines with PLC control and advanced sensors offer greater precision.
- Format flexibility: For companies working with multiple packages, machines with quick settings and programmable recipes make production changeovers easy.
MarCoPack offers automatic and semi-automatic filling solutions designed to adapt to the specific needs of each industry. If you are looking to optimize your production and reduce waste, contact our technical team for advice.
Jose Martínez
Director Oficina Técnica MARCOPACK
