Core idea: Source material control + scheduled maintenance + standardized operation + environment management + advance spare parts preparation. Fundamentally reduce faults such as inaccurate metering, dripping, bottle jamming and malfunction.
1. Material Preprocessing (Source of Most Faults)
Many filling faults are not caused by machine breakdown, but by material impurities, viscosity and bubbles.
1. Install filtering devices: Fit feed pipelines with filters with proper mesh precision according to materials. Clean filter screens every shift to prevent particles from scratching pistons, pump bodies and seals, and avoid valve jamming.
2. Control material temperature and viscosity
- High-viscosity materials (honey, paste, syrup): Preheat to constant temperature in advance. Do not fill cold materials directly to prevent metering fluctuation and excessive pump load.
- Foam-prone materials (fruit juice, laundry detergent): Reduce feeding flow rate and enable dive filling & suck-back anti-drip function to lower false metering caused by bubbles.
3. Never leave materials in pipelines / hoppers for a long time
Empty and clean after each shift. Do not keep syrup, protein or solid-containing materials inside pipelines overnight, to avoid crystallization, drying, valve port blockage and seal wear.
4. Corrosive materials: Confirm matched wetted parts (PTFE seals, 316L stainless steel). Circulate and flush pipelines immediately after production to prevent corrosion perforation.
2. Pneumatic System Prevention (Focus for Pneumatic Models)
80% of stuttering movement and metering drift of pneumatic filling machines come from air source problems.
1. Keep air pressure stable at 0.4–0.7MPa. Install pressure regulator if pressure fluctuates violently.
2. Drain water from air compressor triple unit (oil-water separator) every shift, to stop water and oil entering cylinders and solenoid valves, which leads to rusty valve cores and cylinder jamming.
3. Inspect air pipes regularly. Replace hardened, cracked or leaking joints promptly; keep air pipes away from high-temperature material pipes.
3. Seal & Metering Component Prevention (Core for Dripping & Inaccurate Metering)
1. Set mandatory replacement cycles for seals; replace before failure. Change O-rings and piston seals regularly based on production frequency; shorten cycles for corrosive and high-temperature working conditions.
2. Do not scrape seals and filling nozzles with hard objects during disassembly and cleaning. Fit seals evenly without twisting.
3. Peristaltic pump hoses are consumables. Stock up in advance, check for fatigue cracks and replace preventively before hose burst and leakage.
4. Calibrate filling volume and record data after every material or batch change. Adjust minor deviations early to avoid batch non-conformity.
1. Wipe photoelectric / proximity switches every shift. Splashed liquid and mist may block sensing and result in no filling, overfilling or continuous discharge.
2. Keep electric control cabinet dry; never wash it directly. Add heat dissipation and dehumidification in humid workshops to prevent short circuit of PLC and solenoid valves.
3. Fix cable routing to prevent insulation damage by friction with conveyor chains; regularly check loose wire connectors.
4. Avoid frequent emergency stops and forced manual intervention to reduce impact on PLC and servo systems. Back up programs regularly.
5. Mechanical Conveyor Prevention (Bottle Jamming, Bottle Collision, Position Offset)
1. Apply food-grade grease to guide rails, guide rods and conveyor chains weekly with proper dosage, to avoid grease mixing into materials.
2. Inspect conveyor belts and bottle guardrails regularly, adjust gaps to match bottle types. After bottle type change, run no-load test first and confirm accurate positioning before feeding materials.
3. Clean broken bottles and material scale on conveyor platform timely to prevent bottle jamming and bent filling heads.
4. For tracking filling machines: Regularly check tension of servo motors and timing belts to prevent synchronization deviation and filling head collision.
6. Operational Standard Prevention (Human-induced Faults)
1. Operators shall receive pre-job training. Strictly perform no-load trial run before feeding production. Check air pressure, pipelines and sensors before startup.
2. Do not fill over rated range: Long-term full-limit operation accelerates wear of metering components.
3. Stop machine first for troubleshooting when abnormality occurs. It is forbidden to reach hands into filling zone for fault handling.
4. Full cleaning must be carried out when changing bottle types or materials to eliminate blockage from cross caking.
7. Environment & Long Shutdown Protection
1. Keep workshop clean and dry. Dust and corrosive mist accelerate aging of seals and solenoid valves.
2. Short shutdown (1–3 days): Empty liquid and flush pipelines with clean water. Long shutdown (>7 days): Dry pipelines, protect seals and fully cover machine against dust.
8. Build Advance Spare Parts Inventory to Reduce Downtime
Keep consumable parts in stock: O-rings, filling nozzles, filter screens, peristaltic pump hoses, solenoid valves.
Fault prevention logic: Detect minor issues in advance before shutdown happens. Complete patrol records every shift and build preventive maintenance files.
Guangzhou Shilong Machinery Equipment Co., Ltd. is a professional packaging machinery manufacturer integrating research, design, development and manufacturing. We devote ourselves to introducing advanced technologies, integrating high-quality resources. With sophisticated equipment, rich experience and professional service, we provide customers with customized packaging machines.
We have a complete system covering R&D, manufacturing, sales and after-sales service. Our company specializes in manufacturing packaging machinery including bottle washers, capping machines, labeling machines, sleeve labeling machines, sealing machines, emulsifiers / mixing tanks, water treatment equipment and custom full-automatic & semi-automatic filling production lines for food and packaging industries.
We adhere to the tenet of quality assurance, reputation priority and thoughtful service, and provide personalized products and all-round services for customers.
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