What is a tube filling and sealing machine?
A tube filling and sealing machine is a machine that fills tubes with goods such as gels, creams, ointments, gels, and lotions in various industries. An average tube filling and sealing device will include a hopper to store the product, a piston or plunger to distribute it, a means of closing the final tubes, and capping and labeling functions. Many different types of skincare, hair care, personal care, ointments, adhesives, etc., products are produced using this equipment.
How do tube filling machines work?
The hopper’s contents are transferred to a piston or plunger in a tube filling machine, filling the tubes. Tubes are loaded into a conveyor belt or a holding tray, and the hopper is refilled with the product. The product is dispensed into the tubes as they pass the filling nozzle, which triggers the piston or plunger. When finished, the tubes are sealed and usually labeled before being ejected from the machine. After filling the tubes, they may be secured using the capping and crimping mechanisms in certain tube fillers. The electrical systems that regulate these devices guarantee accurate filling and reliable product quality.
What is the design basis?
The tube filling machine fills and seals tubes containing semi-solid products, such as laminate tubes, aluminum tubes, and plastic tubes. Cream, gel, and ointment will be automatically filled into laminate tubes, aluminum tubes, or plastic tubes, and the tube ends will be sealed using a heat sealer or crimper.
The tube feeder receives the tubes manually. A single transfer chute will transfer tubes, which will be flipped upside down. The spinning wheel transports the tubes to the dosing station. A movable vessel or vat attached to the filling machine will transfer the semi-solid product or the product material. Depending on the filling machine skid design, filling products must be delivered to the filling machine nozzle by vacuum or sanitary pump.
The product in the tube has a variable volume. The filled tube is then carried to the seal station, where a heat sealer or laminate crimper secures the tube’s bottom. The transport system moves the sealed tube out of the machine downstream.
Tube Feeding
The tube filling machine must be built such that tubes may be ergonomically manually loaded into the magazine and automatically fed into the dosing station. The tube must be fed into the dosing station systematically before being vertically positioned on a designated point. The tube’s open bottom side is facing upward.
Dosing Station
◎ Cleaning the tubes’ inside with a vacuum and an adjustable air blow.
◎ The pressurized air supply to the cleaning station must include a final filter.
◎ A vacuum or a sanitary pump built into the filling machine will transfer product materials from a movable vessel or vat to the heated hopper, leaving a minimal product within the vessel when the filling is complete.
◎ The heated hopper with scraper must maintain product consistency and stability of temperature.
◎ The central dosage volume must be adjustable using the adjuster. The operational terminal must be accessible to change the dosage amount and speed.
◎ If a tube is missing from any dosing station, the dosing station should be able to notify the operator.
Sealing Station
Thermos sealing with high-frequency heated jaws and hot air must fully seal plastic tubes. Designer seals may be customized.
Standard, double, and saddle folds require a tube-closing device for laminate tubes and aluminum tubes.
In this station, it should be possible to code the outside tube.
What are the types of tube sealing?
Tube sealing choices are vital when selecting plastic tube-filling equipment. Tube fillers may use hot-air, ultrasonic, impulse, or hot-jaw sealing. For reliable, expert tube seals, it is important to fit the kind of squeeze tube with the appropriate tube sealing tools. Because each tube material responds differently, what performs well for a single-layer COEX tube may not work as well for a cosmetic tube made of polyethylene. Choosing the correct tube filling and sealing equipment might be difficult depending on the industry for a particular product, such as cosmetic tubes, personal care tubes, pharmaceutical tubes, or domestic & industrial tubes.
Let’s check out the two primary choices in today’s tube packaging market.
✅ Hot Air Tube Sealing
As far as tube sealing equipment goes, hot-air tube sealing is the gold standard. This technique produces hot air and blasts into the plastic or laminate tube’s open end. The plastic tube wall is warmed by the hot air, making it soft and malleable. The open end is then welded shut using a pair of tube-sealing jaws to pinch the softened plastic.
This tube sealing technology’s key benefit is its quickness. Hot air sealers have the added benefit of being compatible with the widest selection of laminate or plastic tubes. Hot air tube sealing should operate for tubes made of LDPE, MDPE, HDPE, PP, monolayer, and multilayer, with or without EVOH barrier protection. However, one drawback is that each different-diameter tube needs its own specialized hot air nozzle to fill and seal. Because of this, the price of the necessary change components for the tube run will increase.
The cost of format pieces is small when factoring in the manufacturing run size at an increased throughput. If the manufacturing run size exceeds 1,000 tubes, we suggest this form of tube filler.
✅ Ultrasonic Tube Sealing
Using ultrasonic waves to seal tubes is another common practice in modern packaging. Ultrasonic tube sealers that run separately from a main machine are often the best option when dealing with small volumes of tubes. Hot air sealing is not the only option; ultrasonic tube sealing devices can work with existing tube-filling equipment. Ultrasonic tube sealing is the best option for plastic and laminate tubes. Because of the immense heat produced by the vibration at the tube wall, the polyethylene tube material is malleable. The plastic tube’s open end is welded shut by the combined pressure of the sealing horn and corresponding sealing anvil.
Ultrasonic tube sealers are helpful because they are easy to use, do not need special-ordered components, and can efficiently seal despite product contamination in the seal zone, which may occur if a tube is overfilled, for example. The disadvantage is that tube sealing is slower than hot-air sealing. The maximum sealing speed of most ultrasonic tube sealers is 5 UPM.
What are the main parts of tube filling and sealing machine?
Typically, a tube filling machine will include a hopper to store the product, a piston or plunger to dispense the product, a filling nozzle to fill the tubes, and a device to seal the filled tubes. Additional functions, such as capping and labeling, may be included on certain tube fillers.
Hopper
The hopper stores and supplies product materials into the filling nozzle. It is often designed to hold many products and is generally made of a durable and easy-to-clean material, such as stainless steel. The hopper may also feature a stirring mechanism to help keep the product homogenous and prevent it from settling or separating.
Piston or Plunger
The piston or plunger dispenses the product from the hopper into the tubes. It is mainly driven by a motor or another mechanical device and may be modified to distribute different product quantities. Metals such as stainless steel or aluminum are used to make the piston or plunger because they are robust and can withstand the tension and wear of frequent use.
Filling Nozzle
The part of the machine responsible for filling products into tubes is the filling nozzle. It is usually attached to the tip of the piston or plunger and is made to fit tightly over the tube’s mouth. A flexible gasket or seal may be installed in the filling nozzle to avoid leaking and guarantee precise filling.
Sealing
The machine’s sealing device seals the full tubes after filling the product. Numerous techniques may be used to accomplish this, including thermal sealing, ultrasonic sealing, and mechanical crimping. The sealing is usually customizable to fit various tube types and diameters and is made to provide a solid and dependable seal.
Tube fillers may also include extra characteristics such as sealing and labeling. The capping may entail screwing on a cap or crimping the tube shut, which is used to secure the tubes once they have been filled and sealed. Labels are applied to the tubes using the labeling device, which usually includes details such as the brand, contents, and expiry date. These extra characteristics enhance the final product’s look and presentation.
What is tube filling and sealing machine main applications?
The tube filling and sealing machine has several applications in the personal care, pharmaceutical, chemical, food, and other sectors. It is excellent for products that are packaged in tubes. This machine fills the tube with high-viscosity substances like ointments, creams, gels, or fluids, folds and closes the tube’s tail, then prints codes on the tubes.
What are the types of tube filling machines?
Tube fillers come in various types, mainly defined by how they fill and seal the tubes. The following are a few of the most popular kinds of tube fillers:
✅ Volumetric Tube Filling Machine
This machine uses a volumetric filling approach to fill the tubes with products accurately. Because the dispense amount may be easily adjusted, products with a consistent viscosity and density are perfect for this kind of machinery.
✅ Piston Tube Filling Machine
These machines use a piston or plunger to dispense the product into the tubes. It is typically used for medium to high-viscosity products and can be easily adjusted to dispense different product volumes.
✅ Peristaltic Tube Filling Machine
These tube fillers use a peristaltic pump to dispense the product into the tubes. It is used for products with a low to medium viscosity and is often used for products sensitive to heat or air exposure.
✅ Heat Sealing Tube Filling Machine
These machines use heat to seal the filled tubes. They are for products with a low to medium viscosity and used for products that are sensitive to heat or air exposure as well.
✅ Ultrasonic Sealing Tube Filling Machine
These machines use ultrasonic waves to seal the filled tubes after dispensing them with the product. It is for products with a low to medium viscosity and is often used for products sensitive to heat or air exposure.
✅ Mechanical Crimping Tube Filling Machine
These machines use a mechanical crimping mechanism to seal the filled tubes after dispensing them with the product. This type of machine is typically used for products with a low to medium viscosity and is often used for products that are sensitive to heat or air exposure.
Each type of tube filler has unique features and capabilities, and the most suitable type for a particular application will depend on the product’s specific requirements and the production process.
What are the advantages of using a tube filling machine?
A tube filler has several applications in various industries. Improvements in effectiveness and output are key advantages. These machines can correctly and rapidly fill many tubes, which may boost productivity and decrease turnaround times. Because of their ability to distribute the substances precisely and controllably, tube fillers may also improve in ensuring consistent quality and accuracy of the final result. This method may guarantee that the final goods are up to par and help cut down on waste.
The versatility of a tube filling and sealing machine means that it may be used to package various items and can be a plastic or aluminum tube filler. These machines are often built to be adaptable to handle a wide variety of goods and tube diameters. This can boost your market competitiveness by expanding the type of products you can make.
As a bonus, most tube fillers can use less training to use and are simple to maintain. Also, this equipment is often built to last, with few upkeep and maintenance needs. Tube filling machines may help businesses save time and money by increasing output while lowering waste and fixing rates.
How to choose a tube filler?
Consider several factors when choosing a tube filling and sealing machine to ensure that it satisfies the demands of the product and production operation. While selecting a tube filler, keep the following in mind:
The Density and Viscosity of the Product
Tube fillers come in different shapes and sizes to accommodate a wide range of product densities and consistencies. Products of medium to high viscosity are often filled using piston-based or peristaltic filling machines. In contrast, those of homogeneous thickness and density are better suited to volumetric or gravimetric fillers.
Tube Dimensions and Properties
It’s important to consider the types and dimensions of the tubes used with a filling machine before choosing one. Because different filling machines are designed to handle different tube sizes and materials, it’s essential to ensure the one you choose is appropriate for the tubes you wish to use.
Filling and Sealing Techniques
When selecting a machine, examine the filling and sealing processes used by the tube filler. Different devices adopt distinctive filling and sealing processes, and the best approach depends on the product’s unique specifications and the manufacturing process.
Production Output and Rate
It’s essential to consider the output and manufacturing speed. The ideal machine can reliably and quickly fill and seal the specified number of tubes with no degradation in quality or precision.
Operation and Maintenance Simplicity
When choosing a tube filling and sealing machine, you should think about how easy it is to use and keep up. The ideal machine would have user-friendly controls, need little in the way of routine maintenance, and have few opportunities for breakdown.
Budget and Pricing
Get a tube filler after carefully considering your available funds. The best machine would be functionally and economically efficient while comfortably fitting within the current budgetary limits.
Before deciding on a tube filler, it is advisable to assess the specific demands of the product and the production process and to pick one that is both well-suited to your needs and offers a high degree of value.
MAKWELL Tube Filling Solutions
Our tube filling and sealing machine is designed to fill items into cylindrical tubes of different materials (metal, laminate, and plastic) and then seal the tubes. To meet the demands of the various industries that use tubes for packing, we offer many kinds of tube filler machines, such as the linear tube filling machine and the rotary tube filling machine, which are available in capacities ranging from 35 to 150 tubes per minute. Our tube filler machine can fill a broad range of viscous and semi-viscous substances, such as gel, shampoo, ointment, cosmetics, toothpaste, cream/gel, glue, chocolate, sealant, mayonnaise, etc.
We offer the most up-to-date models of tube filler machines with thoughtful features to make installation, replacement, and upkeep as simple as possible. Isn’t it time to get started? Now is the time to message us and learn more!