The filling machine adopts a pressure-stabilized filling method: the bottle mouth rises to push open the filling valve and start filling, and filling stops when the material rises to the position of the air return hole. After filling, the bottle mouth descends and leaves the filling valve, and the bottle enters the capping machine through another set of transition (transfer star wheel). The anti-rotation blade on the capping machine clamps the bottle neck to keep the bottle upright and prevent rotation. The capping heads on the capping machine perform revolution and rotation simultaneously, and realize the actions of cap grabbing, cap placing, cap screwing and cap releasing under the action of a cam to complete the entire capping process. The finished bottles are transferred from the capping machine to the bottle discharge conveyor chain via the bottle discharge star wheel, and then conveyed out of the two-in-one filling machine by the conveyor chain.
I. Filling Machine
- All rotating discs are made of ANSI 304 stainless steel.
- Large-sized flat toothed bearings ensure stable and reliable operation.
- Filling method: pressure-stabilized filling.
- Filling valves are made of ANSI 304L stainless steel.
- High-precision, high-speed liquid level filling valves with a liquid level accuracy of ≤ ±2mm.
- Fully sealed liquid cylinder equipped with CIP (SIP) circulation channels.
- Double guide rod lifting mechanism with linear bearings and corrosion-resistant, maintenance-free bearings from igus (Germany).
- The power of the filling machine is transmitted via gears from the transmission system inside the frame.
- The liquid level of the filling valve can be easily adjusted by simply changing the length of the air return pipe.
II. Capping Machine
- Magnetic torque capping heads ensure stable and reliable capping performance, with a defective capping rate of ≤ 0.2%.
- The cap feeding guide rail is equipped with a mechanism to prevent reverse caps from passing through and to remove reverse caps. It is also fitted with a set of photoelectric switches; when there are no caps on the cap feeding guide rail, the machine will automatically stop running, effectively avoiding the occurrence of uncapped bottles.
- An infeed bottle detection switch is installed on the capping machine, which is interlocked with the cap-locking cylinder at the connection between the cap feeding guide rail and the cap transfer disc to control the discharge of caps. This ensures that cap feeding stops when there are no bottles, reducing cap loss for the user.
- Efficient centrifugal cap sorting method results in minimal cap wear.
- A cap detection mechanism is provided to control the start and stop of the cap elevator.
III. Bottle Discharge Conveyor Chain
- The drive motor adopts frequency conversion speed regulation and maintains synchronization with the two-in-one filling machine, effectively preventing bottles from tipping over.
- A photoelectric switch is installed on the bottle discharge conveyor chain; in case of bottle tipping, it can control the two-in-one filling machine to decelerate and stop.
IV. Machine Frame
- The frame is made of high-quality carbon steel through welding, and is processed after annealing to effectively prevent frame deformation. The frame surface undergoes anti-rust treatment and painting, with the upper surface covered with ANSI 304 stainless steel plates.
- The transmission system of the two-in-one machine is located under the frame table, driven by a main motor and adopting a gear transmission method.
- The transmission gears are arranged alternately with steel gears and nylon gears.
- An overload protection mechanism is installed on the output shaft of the main motor to effectively ensure machine safety.
V. Control System
a) The electrical control cabinet is made of ANSI 304 stainless steel. The PLC automatically controls the entire process of the two-in-one filling machine, from bottle infeed to bottle discharge.
b) A touch screen is used for operation; production speed, shift output count, fault type, fault location, etc., are all displayed on the screen. It can also automatically record information such as fault occurrence time and fault type.
c) Major electrical components are world-renowned brand products to ensure the excellent performance of the entire machine. All components of the air circuit system are products from Airtac or SMC.
b) A touch screen is used for operation; production speed, shift output count, fault type, fault location, etc., are all displayed on the screen. It can also automatically record information such as fault occurrence time and fault type.
c) Major electrical components are world-renowned brand products to ensure the excellent performance of the entire machine. All components of the air circuit system are products from Airtac or SMC.
Cap Feeding and Cleaning Machine
Working Principle:
- A detection switch is installed on the cap sorter. When the number of caps in the cap sorter is reduced to a certain level, the detection switch sends a signal to start the cap feeder for cap feeding.
- A certain number of caps are stored in the cap hopper. The cap pushing mechanism pushes the caps into the air duct under the action of the air cylinder, and the caps are conveyed to the cap sorter through the conveying air duct by the wind force of the fan.
- The size of the cap dropping opening of the cap hopper can be adjusted by inserting a baffle plate, which is used to control the speed of cap dropping.