Beverage Filling

Beverage Filling at Shibuya

 

 

Pharmaceutical Filling (Inline)

Inline Pharma Filling at Shibuya

 

Filling Systems

 

We have incorporated the latest technology and innovations into the construction of the fillers and cappers that we build. Decades of experience combined with an endless quest for perfection helps us to produce machines of unrivalled quality. This approach allows machines to be designated to optimize a customer's specific requirements for speed, product characteristics and container shapes.

Net Weight

The Weight Filler Model fills bottles/containers to a preset fill weight using a load cell mounted under the bottle rest to directly control the filling valve operation. The weight filler is able to accommodate a wide variety of container and bottle sizes in either in-line or rotary style, depending on the need. Both fillers handle different viscous products, from water/liquid to edible oils and cleaning products. Fill weight is adjusted easily using a keyboard and the machine is totally washable.

Flowmeter

The Flowmeter Filler Model is connected directly to the filling valves to control filling to a constant volume. Weight signals from the flowmeters are received by the weight controller and directly control the opening and closing of the filling valves. If the optional data processor unit is connected the filling weight of each valve can be printed out as a histogram for simple quality control. The product contact path is simple without irregular surfaces - so the equipment is very hygienic and sanitary. Filling volume can be adjusted easily using switches on the operation panel, allowing for quick, efficient change over.

Gravity

Used for carbonated or non-carbonated beverages - the Gravity Filler will fill containers to a preset level. The CO2 gas pressure control system is for maintaining pressure inside the filler bowl at a constant level. There is also a liquid level control system. This system helps to maintain the liquid level inside the filler bowl at a constant level to ensure accurate filling. This type of filler uses a simplified filling valve allowing for efficient washing and sanitation. The valves can be used for both carbonated and non-carbonated beverages, so that replacement of valves is not required when changing from one product type to another. Gentle handling reduces container instability during feeding reducing the foaming of product during filling. This also reduces noise and assures smooth feeding at high rates of speed. Change parts can be replaced by one-touch operation, simplifying size change and reducing changeover times.

Piston

The rotary piston filler accomplishes an accurate fill through the use of a precision machined stainless steel valve, piston and cylinder.  As the turret rotates, the valve and piston are actuated mechanically through a cam profile.

Product flows from the tank mounted on top of the filler, and is supplied to each filling valve. Each port transfers product out to the filling stations located around the circumference of the turret.  A 3-way valve diverts product into the top of the cylinder.  The piston then begins its travel down via a cam profile.  This cam profile determines the volume of product transferred into the cylinder, and can be manually adjusted via a hand crank by the operator. The 3-way valve is rotated 90 degrees, thus positioning the filling channel over the cylinder.  The piston then begins to travel vertically, transferring the product from the top of the cylinder, out through the filling channel and into the filling nozzle.  The bottle, resting on a bottom plate, raises and lowers allowing for a bottom-up fill.  

Mass Flow

The mass flow meter filler is a mass-controlled filler with a custom filling control system developed by Shibuya which provides industry leading accuracy. The programming of the filling valve control has an offset feature that provides compensation for the product in flight at the time of the valve closing. The result of this offset is checked after each bottle fill and recalculated and implemented on the next fill based on the result. This special Shibuya control is implemented on each filling valve and adjusted individually as required, which in turn results in an industry leading fill accuracy.

The use of a mass controlled filler allows quick changeover of fill volume and filling program for different sizes and products. The filling process can be monitored in real time with 100% filling data from the mass flow meter through the HMI and this data can be collected by using a PC. The filling system hardware consists of an individual mass flow meter mounted on each filling station.  Each mass flow meter communicates with a master control unit mounted in the main control panel by means of serial communication via a rotary connector. The filling valve operation is programmable to allow different product flows during the filling cycle to increase the accuracy and to reduce foaming and splashing of the product. The filling valve is pneumatically operated and has two open positions; a bulk (coarse) fill position and a fine fill position. When products that do not foam or splash are being filled the filling valve first opens fully for a preset time to allow the bulk of the product to be filled. The valve is then partially closed, allowing a lower product flow until the offset target weight is achieved, and the valve then closes fully.

 

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