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Overflow Filling

Pressure overflow fillers deliver a quantity of free flowing liquid product into a container until the level reaches a specific
fill level.
Although there may be slight variations in the sizes or shapes of bottles and jars, it is frequently desirable to have the fill
line at the same height on each container so that all of them appear to be filled exactly the same when they are on the
display shelf. Some manufacturers deliberately add extra product and overfill some of their "see through" containers in
order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of
Molding and forming techniques can cause minor irregularities in the sizes or shapes of rigid glass and plastic bottles
and jars, and some semi-rigid containers may also change their shape and volume slightly during the filling process. It is
frequently more economical to use additional product in the oversized containers than it would be to more closely
control the forming processes. Constant level filling techniques compensate for the minor changes and variations in the
containers and produce the uniform appearance that is important in the sale of many products in ?see through?

Fill to Level
Pure gravity is not only one of the oldest and simplest
constant level filling methods, but it is also one of the most
accurate ones for filling free-flowing products. Accutek?s
APOF fillers give you the option to eliminate the
recirculation of the overflow product, and can hold aeration
of the product to a minimum.
Pure gravity filling can be used for most still liquids and
some semi-solids. Products with consistencies as heavy as
catsup or mustard can be filled in this way, but care must be
taken with the heavier products to assure that the
temperature and consistency of the product is maintained at
a level at which the product flows freely and evenly.
Although the constant level fillers can be adjusted to
automatically operate at slower speeds when the product
flows more slowly, this change in rate of flow can affect the
timing of the conveying system and other machines in the
packaging line.
The product flow is produced in the pure gravity system by
locating the product supply tank high enough so that the
forces of gravity can be used to move the product through
the feed mechanisms into the packaging line.
The flow is started and stopped by the action of a spring
loaded filling valve that is opened by the force of making
contact with the top of the container. This is achieved by
lowering the filler head down on the top of the container with
a pneumatic powered diving head. When the pressure of the contact is sufficient, the spring opens the filling valve and
the product flows from the supply tank into the container. The air and any foam that is formed through product filling
turbulence in the container, is forced out through the vent tube or overflow port, as the product enters the container. The
product will continue to fill the container and overflow through the overflow port until the diving head raises and the valve
shuts. When the contact between the filler head and the container is broken the spring closes the filler valve and
prevents dripping of the product as the head is removed from the container and positioned for the next fill. The amount
of time the diving head is lowered and the valves remain open and the product viscosity determines the amount of
product that is dispensed into the container.

The fill level of the container is

determined by the location of the
overflow port in this tube within the neck
of the container. When the product
reaches the overflow port, the fill is
completed, but the flow continues
through the overflow tube until the seal
on the container is broken and the valve
sleeve covers the ports in the filling
nozzle and stops the flow. The diving
head must remain down and the valve
open until liquid product is flowing from
the overflow port to ensure that the
proper liquid level is attained. The
overflow is collected in the overflow
tank and is then pumped back to the
gravity tank or product bulk tank. This
allows for no wasted product and a
chance for any foam that is formed, to be condensed back to a usable liquid state.

The maintenance requirements of the pure gravity filling system are relatively simple. The filler components must be
kept clean and well lubricated, and the bearings, bushings, O-rings, and springs must be replaced when they wear
excessively. The consistency of the product and the free movement of all moving parts are critical for smooth operation.
Underfill may be caused by constriction of the Overflow Port by failure of sufficient product to move into the container
during the time period it is under the filler head.
The use of a gravity tank to provide product flow is the easiest and least expensive way to fill the product, but the
gravity tank may be replaced with a pump. The use of a pump may increase product flow and therefor increase fill
speeds. A centrifugal pump is the normal pump of choice due to it?s ability to pump against a ?dead head? without
continuing to build up liquid pressure. If it is necessary to use a positive displacement pump, an air actuated valve must
be placed on the output of the pump to cause a by-pass to ensure that liquid pressure does not exceed system
capability and cause damage to the machine or the machine operator. It is also possible to use that same air signal to
turn an air driven pump on or off when pressure is needed. The overflow product must now be pumped back to the
product bulk tank to be recycled.
The method that is used to keep the product from leaking out of the nozzle as it moves back and forth is the use of an
O-ring. The O- rings are placed in grooves around the circumference of the nozzle tip as well as within the sliding nozzle
body. There is a separate O-ring for the Fill Port and the Overflow Port. These rings may be made of a number of
different materials that are selected to work best with the characteristics of the products being filled. Testing the
chemical compatibility with the different types of elastomers is required to verify compatibility. The different elastomer
that may be used is also dependent on the temperature range and abrasiveness of the product being filled. The different
elastomers that are commonly used are:
Encapsulated Silicon

Food & Beverages

Cosmetic & Personal Care






Window Cleaners

Cough Medicine

Insect repellent

Fruit Juices
Vegetable Oil

Essential Oils
Nail Polish

Laundry Detergent
Motor Oil


Liquid Coffee

Nail Polish Remover

Air Freshener

Stain Removers

Saline Solution

Vitamin Drinks

Liquid Soap
Sun Tan Lotion

Carpet Cleaners

Food Coloring
Tomato Juice

Hair Conditioner

Fuel Additives

Salad Dressing

Hand & Body Lotion

Mouth Wash

Engine Coolant
Wood Stain

Bubble Bath

Wood Varnish

Liquid Filling Machines and Nozzles

High Quality Nozzles for Liquid Filling Machines & More

Investing in high quality liquid filling machines is a must for businesses,

especially those in industries such as cosmetics, food processing, and wine & beverage. Choose only
Filling Equipment Company, Inc. to provide you with excellent filling equipment today.
With us, you are guaranteed the best parts and equipment for your business at a reasonable price.
Every liquid filler machine has been designed to be efficient and have been made using state of the
art technology.

Expertly Crafted Nozzles for Liquid Fillers

At Filling Equipment Company, we offer a variety of custom-designed, high quality nozzles: all
manufactured to deliver maximum precision.
We manufacture nozzles for our equipment and all other manufacturers machines.

A standard filling nozzle is made out of 316 Stainless Steel (SS), which is better than Grade
304 SS in terms of overall corrosion resistance and is more resistant to pitting and crevice corrosion
in chloride environments. We can also manufacture the product in the following materials: PVC,
Hastelloy & Titanium
Also available are liquid filling nozzles with air cylinder shut-off for an added boost to the liquid
fillers performance
We offer the following types of nozzles:

Type A:

Type B:

Type C:

Type D:

Type E:

Type F:

Type G:

With us, you get a multitude of options that could improve your liquid filling process. So look no further
than Filling Equipment Company for the kind of filler liquid corrosive substances wont easily wear out.
We guarantee high quality nozzles for liquid filling machines and more.