Aerosol Filling Machine

What is the Aerosol Filling Machine?

The aerosol filling machine can fill aerosols, such as liquid, cream, and gas, into the cans with the help of pressure. It often contains several processes, including filling the gas or liquid you need, crimping on aerosol cans, and then adding a propellant. After completing these processes, you can expel the container as a spray.

How Does Aerosol Technology Work?

Aerosol filling technology uses pressure vessels to fill the contents you want to aerosol fill, such as gas and liquid, into an aerosol bottle, and then releases it in the form of spray or foam. Advanced filling technology also uses bag-in-valve (BOV) systems and metered dose inhalation (MDI) to ensure sterile storage and precise quantitative release.

The Structure of the Aerosol Filling Machine

• Tippers

In the aerosol filling machine, Tippers can realize automatic flipping to match the upper and lower programs, achieving flexible and efficient production

• Cappers

The capper in SaintyCo aerosol filling machine can seamlessly close the aerosol valve, which can ensure that the aerosol can will not leak and can resist pressure well.

• Valve Placers

In order to accurately place the aerosol valve on the mouth of the aerosol can, SaintyCo uses valve placers to put the aerosol valve in the correct position.

• Waterbaths

The water bath test tank in the aerosol can filling machine is mainly used to detect whether the contents in the can are leaking. It is done by soaking the can in hot water to see if there are bubbles. This is a very important step for SaintyCo in testing whether the aerosol can is qualified, which can greatly ensure the qualification of aerosol filling.

• Pressure Testers

SaintyCo’s pressure tester in the aerosol filling machine performs pressure tests on the finished products to ensure that the products in the aerosol cans meet the internal pressure standards and ensure the safety of the aerosol cans.

What Does an Aerosol Filling Machine Consist Of?

Protective Structure System

• Stainless steel frame 

As the main supporting structure of the whole equipment, the stainless steel frame is a good choice because stainless steel is corrosion-resistant, strong, and easy to clean. 

SaintyCo generally uses SUS304 or SUS316L stainless steel. These two types of stainless steel can perform better on the aerosol filling machine and better protect the internal precision parts.

• Guard plates

The guard plate can cover the periphery of the equipment to protect the internal components from contamination, and when manual operation is required, it will not touch the precision parts inside.

 It works together with the stainless steel frame to protect the parts of the aerosol filling machine and extend its service life.

• Access doors with shatterproof panels

Aerosol filling machines are usually equipped with a shatterproof viewing window on the access door, so that when your project needs production or maintenance, you can clearly see the internal status of your machine.

• Upper and lower guarding system

This protective structure is equipped with protection systems in both the upper and lower directions, which can more comprehensively protect the operator’s safety, and pollutants will not enter the interior to contaminate the contents that need to be filled in your project.

Transport System

• Anti-static container guide rails

Container guide rails are used to guide aerosol filling bottles to run smoothly on the conveyor line to prevent aerosol filling bottles from falling or shifting.

At the same time, container guide rails generally adopt an anti-static structure, which can prevent sparks from causing explosions when filling some flammable contents.

• Transport conveyor with infeed/outfeed sensors

The transport conveyor is responsible for the smooth movement of aerosol filling bottles in each link of production for your projects. 

Generally, transport conveyor will be equipped with sensors at the import and export to detect whether the aerosol filling bottles have reached the designated position, which can effectively prevent repeated filling or empty filling.

• Star wheel or indexing conveyor

Aerosol filling machines generally include two configurations, one is In-Line Indexing and the other is Rotary Indexing, and they also have different conveying methods.

In-Line Indexing generally uses the Indexing Conveyor, which can accurately locate and is suitable for large-capacity aerosol filling bottles.

Rotary Indexing uses the Star Wheel System, which is suitable for small-capacity aerosol filling bottles that require high-speed filling.

Filling System 

• Product Filler

Product Filler, also called a liquid filling head, is responsible for filling the liquid filler you want to fill into the tank. This component can achieve precise dosage filling and avoid foaming and leakage.

• Valve Inserter

The valve inserter is responsible for accurately installing the valve at the mouth of the filling bottle in the aerosol filling machine. This component can control the injection of the product and has a good sealing effect.

• Propellant Filler

Propellant filler, also called a gas filling unit, is mainly used to inject propellant into aerosol cans to help promote gas spray. High-precision metering and control systems are usually used in this module to ensure accurate dosage and stable gas pressure for your project.

• Crimper

The crimper is a core module in the aerosol filling machine. It is used to seal the valve cap. In this module, the cap must be evenly and firmly pressed to avoid leakage.

• Ball bearing dropper with agitation

The ball bearing dropper is an additional module in an aerosol can filling machine. Not every aerosol filling machine will be equipped with a Ball bearing dropper with agitation, but if it is equipped with this module, it can help your project’s filling material to be mixed evenly.

Safety System

• Emergency stop circuit

The emergency stop circuit is a safety device that must be equipped for all industrial automation equipment, including aerosol filling machines. When equipment fails, the emergency stop circuit can immediately cut off the circuit to ensure the safety of your operators.

• Explosion-proof

Since some flammable gases are often filled in aerosol filling machines, explosion-proof equipment is also essential. It can effectively prevent explosions and provide safety protection for your project.

• Door interlock monitoring

When the equipment is running, door interlock monitoring can prevent the operating door from being easily opened, which can effectively prevent some safety accidents.

• Overload protection

Overload protection is a very important safety feature in aerosol filling machines. When the system load of the aerosol filling machine is abnormal, it can automatically detect the abnormal situation and immediately stop the operation of the equipment, which can effectively prevent equipment damage and safety accidents for you.

Control System

• PLC Control Panel

The PLC control panel is the core control module of the aerosol filling machine, which can centrally manage the operation of the entire equipment.

• Touchscreen HMI

The touchscreen HMI is a visual control of the equipment through real-time monitoring. Operators can view the operating status of the equipment and set parameters through the touch screen.

• Data recording/traceability function

This module can save the information of the production process in real time and record every product’s information. When you need this information, you can call it up at any time.

Optional Functional Modules

• Can orientation checkers

This device can check whether the can is in the correct direction, so you can achieve accurate filling.

• Coding/vision/weight check station

These modules work together to achieve a comprehensive inspection of logo, quality, appearance, etc., effectively ensuring the quality of your products.

What Are the Categories of Aerosol Filling Machines

• High-speed  Aerosol Filling Machines

The high-speed aerosol filling machine is the most common aerosol filling solution. The production of this type is high, which can reach 80 CPM at least. It has a stable cycle time so that you can predict the production easily and prevent wasting time.

• Advanced Bag-on-Valve Filling Machines

Advanced Bag-on-Valve filling systems can be divided into three categories: Bag on Valve Aerosol Filling Machines, Advanced BOV Filling with Servo Motor Control, and UTC Refrigerant Filler.

 Based on valve bag filling technology, advanced Bag-on-Valve filling systems can achieve pollution reduction and recycling.

• Bag on Valve Aerosol Filling Machines

SaintyCo uses BOV technology to completely isolate the propeller gas from the contents of the aerosol filling bottle, which can better retain the value of the contents you want to fill and achieve a 99% distribution rate.

The spraying direction is also very flexible. Even if the aerosol filling bottle is inverted, it can be sprayed out, which is very convenient. If you need aerosol filling, the BOV aerosol filling machine is a very good choice.

• Advanced BOV Filling with Servo Motor Control

The advanced BOV aerosol filling machine combines BOV technology and a servo motor control system, which can achieve high-precision dosage control and meet the sterility requirements of medical grade. This aerosol filling is often used in nasal sprays.

• UTC Refrigerant Filler

The UTC refrigerant filling machine adopts advanced UTC filling technology and can be controlled by PLC programming. The operation of this aerosol filling machine is very simple and easy to use.

SaintyCo also uses photoelectric sensing to ensure accurate filling every time, and the output is also high, which can greatly reduce the labor cost for your project.

Special Use of  Aerosol  Filling Machines

• Under Cap Aerosol Filling Machines

Before installing the valve, the under cap aerosol filling machine completes the filling and sealing. This aerosol filling machine of SaintyCo does not require the installation of valves in advance, and can be carried out in a closed environment to achieve vacuum filling.

 If you want to produce products such as fire extinguishers and refrigeration tanks, the under cap aerosol filling machine is your best choice.\

• Portable Canned Oxygen Filler

Portable Canned Oxygen Filler is designed to store high-purity oxygen. This oxygen tube is small and portable, with very high cleanliness. It is also equipped with a pressure relief protection system to provide safety for your project.

Pharmaceutical Aerosol Filling Machines

• MDI Pharmaceutical Aerosol Filler

This aerosol filling machine is designed for Sterile Filling Lines with Laminar Flow. This content is mainly used to treat respiratory diseases such as asthma. This equipment can strictly control the metering and has high requirements for the cleanliness of the environment, which can meet the requirements of GMP.

If you are a manufacturer engaged in the production of medical devices, MDI Pharmaceutical Aerosol Filler can meet the high precision and high cleanliness requirements of your project.

• Sterile Filling Lines with Laminar Flow

Using laminar flow technology, Sterile Filling Lines with Laminar Flow can prevent contaminants from entering and create a Class A clean environment. During the filling process, this aerosol filler can strictly control temperature and pressure to ensure product quality for your project.

The Application of the Aerosol Filling Machine

• Personal Care Aerosol Industry

Aerosol filling machines have many applications in the field of personal care. They can be used to fill daily household products such as hair spray and shaving foam. They can achieve high-precision aseptic filling for you and ensure the quality of your products.

• Automotive Aerosol Products

Aerosol filling machines can also be used to fill car maintenance products such as car cleaners and lubricants. Generally, such filled products are corrosive and volatile, and have high requirements on filling accuracy, leakage prevention and explosion prevention of aerosol filling machines.

• Food Aerosol Industry

In the food industry, aerosol filling machines can be used to fill products such as edible spray oil and cream spray. When filling such products with aerosol, higher requirements are placed on hygiene and material safety. At the same time, some clear modules need to be configured for you to achieve daily cleaning work.

• Household Products Aerosol Industry

In the food industry, aerosol filling machines can be used to fill products such as edible spray oil and cream spray. When filling such products with aerosol, higher requirements are placed on hygiene and material safety. At the same time, some clear modules need to be configured for you to achieve daily cleaning work.

• Technical Aerosol Industry

This type of aerosol filling machine can be used in various industrial fields, such as aerosol paint can filling machines, which can be used in the field of decoration manufacturing for industrial spraying.

Because industrial products usually have the characteristics of high pressure, flammability and high viscosity, this type of aerosol filling machine has high requirements for safety and sealing.

Conclusion

Aerosol filling machines are devices that can automatically fill products in the form of gas, liquid, etc, into aerosol cans. They can achieve high-speed and precise dosage filling. It has many applications in various fields, such as pharmaceuticals and industry.