Engine oils, greases, paints, solvents, agrochemicals and cleaning chemicals are packed into bottles, cans and drums every day. Unlike food or water, these products bring hazards such as flammability, corrosiveness and toxic fumes. Filling machines for these products must address safety as well as accuracy.
Understanding Your Product
Before choosing a machine, know your product’s properties:
- Viscosity and how it changes with temperature
- Flammability and flash point
- Corrosiveness to metals and seals
- Fume generation
- Foaming tendencies
These properties determine materials, filling method and safety features.
Filling Methods
- Weigh filling: accurate for lubricants and chemicals, especially in larger packs and drums.
- Piston filling: suits viscous products like greases and thick oils.
- Flowmeter filling: fast and accurate for medium viscosity liquids.
- Gravity filling: suitable for thin, non-foaming liquids.
Flameproof Requirements
For flammable products, electrical components must be suitable for hazardous areas. This may include flameproof motors, enclosures and intrinsically safe sensors. Pneumatic operation can reduce electrical risks. Proper earthing prevents static build-up.
Material Compatibility
Corrosive chemicals require resistant materials such as SS 316, PTFE, or special plastics. Seals and gaskets must be compatible with the product.
Fume and Spill Control
Fume extraction protects operators. Drip trays and spill containment keep the work area clean and safe.
Container Handling
Containers range from small bottles to drums. Heavy containers need robust conveyors or roller systems. Drum filling often uses lances that fill from the bottom up to reduce splashing.
Capping and Sealing
Containers may use screw caps, induction seals or bung closures. Ensure capping equipment suits the container and product.
Labelling and Hazard Information
Chemical products need hazard labels. Labelling machines must apply labels accurately and durably, resistant to product contact.
Handling Viscosity Changes
Lubricants and greases thicken in cold conditions and thin in warm conditions. Weigh fillers handle this automatically because they measure by weight. Volumetric fillers may need adjustment throughout the year, and some plants warm product tanks slightly to keep viscosity consistent. Heated hoppers, insulated pipework and controlled storage areas help maintain stable product behaviour. Recording product temperature at the filler alongside fill weights makes it easier to see when adjustments are needed.
Drum and Pail Filling
Larger packs such as 20 litre pails and 200 litre drums need dedicated equipment. Drum fillers usually work on a weighing platform with a filling lance that enters the bung hole. Bottom-up filling reduces splashing and fume release. For pails, semi-automatic fillers with weighing scales are common. Handling heavy containers safely requires roller conveyors, lifting aids and proper floor space.
Labelling Durability
Labels on lubricant and chemical containers must resist oil, solvents and handling. Choose label materials and adhesives designed for chemical resistance, and test them with your product before committing to large print runs.
Cleaning Between Products
Switching between different oils or chemicals can cause cross-contamination. Plan flushing procedures, and dedicate filling equipment to incompatible product groups where necessary.
Safety Practices
Train operators on product hazards, use personal protective equipment and maintain clean, ventilated filling areas.
Hilden supplies filling machines for lubricants and chemicals with appropriate safety features and can help you choose equipment suited to your products’ hazards and pack sizes.
