Filling machines in modern production: Function, types, and areas of application

Filling machines fill liquids, powders, pastes, or solid materials into suitable containers such as bottles, cans, or pouches. Aseptic filling and maximum process reliability are essential, especially in pharmaceutical and cosmetic production. Modern systems operate quickly, efficiently, and hygienically, ensuring that each product is precisely dosed and securely sealed.

Definition: A filling system is an automated technical installation that doses, fills, seals, and, if required, labels or inspects products such as liquids, pastes, powders, or solid materials.

In Which Industries Are Filling Systems Used?

Filling systems are indispensable in numerous industries – particularly in the food, pharmaceutical, cosmetics, and chemical sectors. Depending on the application, they may include additional functions such as sterilization, capping, labeling, or quality control. In highly regulated fields like pharmaceuticals, they form part of integrated aseptic systems that ensure maximum product quality and safety. Aseptic filling systems operate in cleanroom environments under controlled conditions to eliminate contamination.

How Does a Filling System Work?

The functionality of a filling system varies depending on the type of product and packaging format. Generally, the process includes the following phases:

1. Product Feed: The product is transported from a storage tank to the filling station.
2. Container Positioning: Empty containers are automatically supplied and precisely positioned.
3. Dosing and Filling: The product is filled into the container with exact dosing.
4. Sealing: The container is securely closed.
5. Labeling and Inspection: Optionally, labels are applied, and the fill level, seal integrity, or weight is checked.

Comparison: Blow-Fill-Seal Technology

The Blow-Fill-Seal (BFS) technology is a specialized process for aseptically filling liquid or semi-liquid products. Rommelag is recognized as a pioneer of this technology. All process steps – forming, filling, and sealing – take place fully automatically within a closed, sterile system.

In the BFS process, a container is first formed using air pressure or vacuum (Blow), then filled with a sterile product (Fill), and finally hermetically sealed (Seal). The entire process occurs under aseptic conditions and without human intervention.

Due to its high sterility and process reliability, BFS technology is widely used in the pharmaceutical industry, for example, for inhalations, infusion solutions, or eye drops. It is also used in the cosmetics and food industries when product safety and cleanliness are top priorities.

Types of Filling Systems

Filling systems can be categorized according to three main criteria:

1. By Product Consistency

• Liquid Filling Systems: for water, juices, milk, or chemicals.
• Viscous Product Fillers: for thick liquids such as creams or pastes.
• Powder and Granule Filling Systems: for free-flowing products like coffee or washing powder.
• Piece Goods Filling Systems: for small solid products such as candies or tablets.
  
  

2. By Filling Method

• Volumetric Filling: dosing based on volume (e.g., piston fillers).
• Gravimetric Filling: dosing based on weight, ideal for high-value products.
• Level-Based Filling: filling up to a defined optical level.
• Vacuum Filling: avoids air bubbles in foamy products.
• Pressure Filling: used for carbonated products such as sparkling water or beer.
• Blow-Fill-Seal Filling: aseptic, fully automated filling method for sterile liquids.
  
  

3. By Degree of Automation

• Manual Systems: suitable for small batches and test production.
• Semi-Automatic Systems: partially automated with operator input for selected steps.
• Fully Automatic Systems: highest output with minimal staffing requirements.

Note: Conventional filling lines may use monoblock systems that combine multiple process steps. Rommelag, however, uses the BFS technology, which integrates forming, filling, and sealing within a single aseptic process.

What Are Aseptic Filling Systems?

Aseptic filling systems ensure that products such as vaccines, eye drops, or UHT milk remain entirely microorganism-free. Both the product and the packaging are sterilized before filling. The entire process occurs in closed systems featuring HEPA-filtered laminar airflow, validated sterilization processes, and continuous process monitoring. This technology is indispensable in the pharmaceutical, food, and cosmetics industries.

Contract Filling

Companies that do not operate their own filling systems can rely on specialized service providers. Rommelag CDMO offers contract manufacturing and aseptic filling services – ideal for businesses aiming for maximum product quality without investing in in-house equipment. This model provides maximum flexibility during production peaks and access to specialized expertise.