A Comprehensive Guide to Tube Filling Machines

Do you wear lotion, toothpaste or glue that comes in plastic or metal tubes? How does all that cream, or liquid, or sticky, stuff get into the tubes? And that’s thanks to such awesome machine called tube filling machines!

You can read about tube filling machines in this tutorial and learn all about it. So, we’ll also look at the various versions of these cool machines. Well, put out some toothpaste and sit tight and watch!

What is a Tube Filling Machine?

Tube filling machine is the machine which fills tubes with liquids, gels, pastes, or creams. Machines are used to pipe hand lotion, shampoo, paint, and even cake icing in tubes.

Tube filling is very easy and fast thanks to the machines. Every piece of creamy material, pre-tubing-machines, was spooned or squirted in tubes manually. It was sloppily slow! The machines came along and radically transformed all that.

So, How Tube Filling Machine Works?

Tube filling machines automate or automatically fill tubes. This is what makes filling thousands of tubes very quick and reliable. This is what goes into it:

• Empty tubes go in to the machine, either automatically or manually.

• The machine points the open ends of the tubes upward for squirting.

• Depending on how watery/smooth the product, different filling systems fill each tube with the ideal quantity.

• Once filled, each open tube is closed and no liquid escapes or spills! Sealing can be performed with heat, ultrasound waves, or pressure.

• You might also add other operations such as capping, labeling tubes or packing tubes.

• At last the sealed filled tubes fall from the machine onto a conveyor belt or robot arm, to be boxed!

Tube filling machines can pump tube after tube through dozens of automatic steps. The machines also ensure the right quantity of product is delivered to each tube and a tight sealing. No more wet hand-filling!

Tube Filling Machines Types:

You can buy several different tube fillers on the market. Some are pretty basic and others really cool! A business’s demands and number of tubes it has to fill will determine the type. Let’s consider a few of the more typical ones:

Semi-Automatic Tube Filling Machines

These are starter-level tube filling machines suitable for companies with limited production volumes. As the name suggests, they automate parts of the filling and sealing operations but also require manual intervention.

Key Features:

• Compact, benchtop design
• Lower investment cost
• Manual loading and unloading of tubes
• Automated filling and sealing modules
• Touchscreen display for controlling operations
• Better suited for small batch production

Applications:

Great for startups doing trial runs, lab testing, small businesses launching new product lines, etc. where output volumes are modest.

Fully-Automatic Tube Filling Machines

These advanced machines handle the entire tube packaging process automatically with minimal need for human supervision. They are ideal for medium to large scale production environments.

Key Features:

• Automatic tube feeding and orienting system
• PLC/microprocessor based programmed control
• Servo motors for precision filling
• Integrated sealing modules like ultrasonic or heat sealing
• Higher output capacity - thousands of tubes per hour
• Advanced features like weight checking, leak detection
• Minimal human intervention needed

Applications:

Mass production environments like pharmaceutical, cosmetics and food factories which require high volumes and compliance with cGMP/quality standards.

Rotary Tube Filling Machines

As the name suggests, these high-speed machines use a rotary table design to achieve remarkably high output when filling and sealing tubes.

Key Features:

• Automatic rotary table for tube handling
• Robotic pick-and-place systems for loading and unloading
• Super high output - upto 40,000 tubes per hour
• Ideal for round/cylindrical tubes
• Smaller footprint than linear machines
• Advanced servo control and pneumatics
• Easy size changeovers

Applications:

Heavy-duty mass production environments like pharmaceutical plants, cosmetics manufacturing units where output needs to be maximized.

This shows how tube fillers have evolved from simple semi-automatic units to highly precise, high-volume rotary machines to cater to different production environments.

Tube Fillers Semi Auto vs Fully Automatic

A big consideration when you need to choose a fully automatic or semi-automatic tube filler if your business is beginning to fill tubes. Choosing which automation level is best for you can be overwhelming!

We’ll run a guide here that compares semi and fully automated tube fillers on various metrics. And by the end you will be fairly familiar with which kind is best for you. Let's dive in!

Output Needs

• High speed production capability are offered by fully automatic tube fillers. With full automation they can make thousands of filled tubes per hour. This makes them perfect for giant mills filling tons of tubes per day.
• Semi-automatics can provide smaller volumes, of hundreds of tubes per hour. They involve some manual intervention by operators. So they are best for small companies with short production runs or pilot programs.

Labor Costs

• Because the automated tube fillers don’t require a lot of human attention, the cost of labour can be drastically reduced. There are only a couple of workers required for repairs and loading of raw materials.

Investment Budget

• Because of their automated controls, sensors and servo controls, fully automatic tube fillers are expensive to start with. Installation and integration add to the costs.
• Semi-automatic machinery uses cheaper mechanics and automation. So, cheaper to purchase and deploy for companies on a budget.

Changeover Time

• Full automation means size changeovers are extremely rapid in fully automated tube fillers. Switch between tubes size in minutes without disruption.
• In semi-automatics it is slower to switch parts to interchange the tube sizes. During lengthy transition periods, production must be shut down completely.

Product Variety

• Fully automated fillers can handle a range of products of varying viscosities, texture and ingredients. Switchovers between products are also lightning-fast.
• Semi-automatic equipment is preferable for organizations that are not selling many products and there are few product changeovers. This is not an easy thing to switch over products on a regular basis.

How Do Test Tube Filling Machines Operate?

In test tube fillers, the machine is equipped with special cylinders which together fill and seal the tubes:

The test tubes must be in racks on a rotating table or belt that hold them upright.

1. Tubes drop, one by one, through a pump. Depending on the volume specified, a pump or syringe injects liquid into each tube.
2. To prevent spills, tubes can be temporarily sealed when filled.
3. Next, the loaded tubes slide into a sealing machine, where they receive a permanent cap or seal.
4. And finally the sterilized and filled test tubes are pulled out for science experiments!

High-tech test tube fillers can fill 1200 tubes an hour! Computer monitors regulate the flow of liquid through every tube.

What Are The Advantages of Buying Tube Filling Machines?

This is not all there are benefits of investing in tube filling machines that can make manufacturing much better:

Much Faster Speed

Automated tube fillers can package thousands of tubes per hour. This is considerably faster than filling them by hand. It drives more production.

More Efficient

As humans work – at minimum – it’s less expensive to labour and thus, fewer human mistakes. Tubular fillers provide increased efficacy.

Extremely Accurate

Powerful pumps such as piston pumps fill tubes correctly and consistently each time. Such quality control is essential.

Cost Savings

More capacity, less waste, less labour — all big savings when compared with manual filling.

More Versatile

The majority of tube fillers support a range of liquid viscosities, tubes sizes and ingredients. It’s multipurpose which means you can fill many things.

Improved Hygiene

Cloned systems are automated and keep contamination to a minimum. This is critically important for foods, pharmaceuticals, and skincare products. Even the machines themselves are easier to disinfect.

Because of these tremendous benefits, tube filling machines are a good decision for any type of manufacturing plant.

Tube Filling Technology Advances in technology

In the past several years, there have been incredible developments in tube filling equipment, new technologies based on consumer tastes and industry needs:

High-Speed Sealing Mechanisms for High Speed Sealing

• Sealing Linear seal for laminate squeeze tubes
• Ultrasonic sealing for heatless air-tight seals.
• Induction sealing for tamper-proofing

Automation and Robotics

• Automated product changeover via robot.
• Defect-detection vision systems
• Automatic tube loading and unloading.

Precision Filling Technology

• Servo pumps for precise fill-points
• Laser fill level measurement.
• Piston filling for thick pastes.

Industry 4.0 Integration

• IIoT integration for data collection
• Artificially intelligent sensors for condition reporting.
• AR-enabled smart glasses for operators.
• Artificial intelligence to inspect things visually.

Custom-Engineered Solutions

• Multi-tube filling heads

Flexible, Modular Design

• Modulated quick changeover modules for various tube sizes.
• Designed heating/cooling jackets for goods.
• Interfacing with peripherals such as printers.
• Customized customer solutions for different requirements.

Innovation being a priority, tube filling technology continues to change according to the evolving customer requirements and business trends.

How Tube Filler Suppliers Can Serve Customers’ Needs?

Tube filler manufacturers are here to make things right, at a fair price. Below are some innovative strategies that they can deliver on delivering customers:

Deliver Custom, Dynamic Solutions

There is no such thing as universal. For different types of products there should be different tube lengths, materials, filling rates, etc. If we are able to provide customers with the exact features they want, it is a lot of good.

Design User-Friendly Machines

Automating complicated processes and simplifying the controls improves user-friendliness and maintenance. Disposable modules reduce downtime, too. All these contribute to a better experience.

Offer Unlimited Technical Support

With 24-hour service, video instruction, and access to knowledgeable technicians, clients are sure of their confidence. This builds loyalty.

Keep Up with Industry News

Informing themselves on current tube packaging styles, technology, trends, consumer requirements, and laws enables manufacturers to design innovative solutions that enable customers to stay ahead.

Get the Quality Right The First Time

We’re strict with our quality controls, parts from known suppliers, and machines that are built tough so that performance doesn’t fluctuate or breakdowns are common. And this brings back business.

Solutions In Various Industries Applications

Tube fillers can support multiple applications in manufacturing:

Pharma and Health Care

• Ointments, gels, creams
• Medicinal pastes, balms
• Petroleum jelly
• Toothpaste and gels
• Supplements

Skin Care and Make-up: Cosmetics and Personal care

• Skin creams, lotions
• Hair styling gels
• Lip balms
• Shaving creams
• Sunscreens

Food and Beverage

• Sauces, dressings, condiments
• Cooking pastes/purees
• Jams, honey, chocolate spreads.
• Dairy products, such as cream cheese.
• Tomato paste, fruit juices.

Chemical and Industrial

• Lubricating greases, adhesives
• Sealants, epoxy fillers
• Solids and liquids with high viscosity.
• Automotive products

What To Expect from Tube Filling Equipment?

Technology is evolving so what’s the future for tube fillers? Here are some possible patterns:

Tube Filling Machine Market Report 2023-2028

• With the rising growth of e-commerce and D2C brands, the demand for tube fillers will continue to expand across countries. We will require full-sealing packaging turnkey solutions.
• Sustainable packaging will spawn recyclable and biodegradable tube materials such as bio-plastic. Machines will need to be trained to work with these materials.
• Full-process automation – robotic loading/unloading, inspection with vision and guided conveyors, will prevail, eliminating the human component.
• IIoT, data analytics, machine learning will be integrated with the self-diagnosis, maintenance predictively, and optimization.
• Adjustable, quick-changeover machines will allow mass customization for customized packaging.
• Small and light tube fillers will suit distributed production systems and onsite production.

FAQs

Is there a machine to pour plastic and laminated tubes?

Yes, you can find most tube fillers which work on plastic, laminate and aluminum materials. But best settings are for different types of materials. Superior fillers mean that you can swap tubes in a hurry.

Where is the distinction between Ultrasonic and Heat Sealing?

Ultrasonic sealing uses vibrations at high frequency to create a reliable seal without external heat. This avoids heat damage to sensitive goods. It is faster, less energy consuming and typically seals better than traditional heat sealing.

How to avoid bad tube sealing?

The right sealing pressure needs to be applied for the tube, product thickness, etc. Amplification, pressure, and time need to be tuned fine. The sealing components are maintained with proper care to prevent premature failure. The automated seal checking also mitigates the defects.

What are some Tube Filling troubleshooting steps?

Problems such as overfilling, low output or jams may result from damaged pump components, out-of-position sensors or clogged nozzles. Be sure that the pump is properly running, nozzles are inspected and cleaned to prevent clogs. The nozzle needs to match the product. You can get a troubleshooting guide from the machine maker.

How frequently should you maintain?

This ensures that tube fillers perform efficiently and maintain their durability. Every day after using cleaning moving parts as necessary lubrication and replace parts that wear out and fillers calibration. The manual also includes the specific schedules of servicing of each model.

Final Thoughts

Working with a reputable company such as Makwell ensures that you will have access to knowledgeable technicians for maintenance assistance and repairs. This ensures customers complete security.