| Customization: | Available |
|---|---|
| Type: | Count Filling Machine |
| Automatic Grade: | Automatic |
| Quantity: | |
|---|---|
The High-Capacity Gel Filling & Mixing System is a specialized solution designed for producing alcohol-based hand sanitizers, disinfectant gels, and medical-grade disinfectants in 600ml plastic bottles. Engineered to handle high-viscosity materials (10,000–50,000 cP), this integrated system combines precise mixing, homogenization, and piston filling, ensuring consistent gel quality, accurate fill volumes, and compliance with strict hygiene standards. Ideal for pharmaceutical, personal care, and household chemical manufacturers, it supports end-to-end production from raw material blending to final bottle packaging.
Dual-Function Mixing & Filling:
Mixing Module: High-shear homogenizer (3,000 RPM) with dual-stage rotor-stator ensures uniform gel consistency (viscosity variation ≤5%), capable of blending alcohol, thickeners, and antimicrobial agents.
Filling Module: Servo-piston fillers with heated manifolds (30–50°C) achieve fill accuracy within ±1% of target volume (600ml ±6g), critical for costly formulations containing aloe vera or glycerin.
High-Viscosity Handling:
Auger-feed nozzles with anti-suction technology prevent drip residue (≤0.2g/bottle), while positive displacement pumps maintain steady flow rates for gels up to 50,000 cP.
Automatic viscosity compensation adjusts filling speed in real-time, reducing cycle time by 20% compared to standard piston fillers.
Sanitary Design & Compliance:
316L stainless steel contact parts and FDA-compliant seals, with quick-release mix tank (CIP/SIP capable) for 30-minute sanitization cycles, meeting EU Cosmetics Regulation (EC 1223/2009) and NSF 3-A standards.
Explosion-proof motors and static-dissipative surfaces comply with ATEX/IECEx for flammable alcohol blends (ethanol content ≥60%).
Intelligent Control System:
PLC-based HMI with recipe management stores 100+ formulations (gel density, fill volume, mixing time), enabling 15-minute changeovers between sanitizer and lotion production.
In-line viscosity sensor and load cell feedback ensure real-time quality control, generating traceable reports for GMP and ISO 22716 audits.
Ideal for producing viscous hygiene products:
Personal Care: 600ml HDPE bottles for hand sanitizer gels with aloe vera, supporting pump dispensers and flip-top caps.
Pharmaceuticals: Medical-grade disinfectant gels for hospital use, with optional nitrogen flushing to extend shelf life by reducing oxidation.
Household Cleaning: Large-format gel bottles for multi-surface disinfectants, compatible with embossed HDPE and PET containers.
The system integrates with upstream raw material storage and downstream labeling/packing lines, forming a seamless production ecosystem for high-viscosity liquids.
Q: Can this system handle alcohol concentrations above 80%?
A: Yes, the explosion-proof design and stainless steel construction are certified for ethanol concentrations up to 95%, with nitrogen purge optional for oxygen-sensitive formulas.
Q: What is the minimum batch size for mixing?
A: The mix tank supports batches from 50L to 1,000L, ideal for both small-scale R&D and large production runs.
Q: How is gel consistency monitored during filling?
A: An in-line viscometer measures real-time viscosity, triggering automatic adjustments to filling pressure and speed to maintain uniform flow.
Q: Are custom nozzle designs available for foam sanitizers?
A: Yes, our engineering team can design specialized nozzles for foaming agents, ensuring consistent output for hybrid gel-foam formulations.
| Final Products | |
 | Detergents & Corrosive Liquid. Suitable : detergent, shampoo, dishwasher, liquid soap, bleach, clorox, toilet cleaner .etc Bottle Material : PE PP Bottle Bottle Type : Round / Square / Unique Cap : Screw cap Label : Sticker Label |
| Containers and Specifications | ||||
| Project Name: Full-automatic Viscous Liquid Filling Machine | Oil and Fat Products / Daily Chemicals / Corrosive Liquid | |||
| Bottle Material | Bottle Shape | Filling Range | Capacity | Filling level (mm) |
| PET / PP / PE / Glass / Metal | Round / Square / Unique Shape | 200ml-30L | As request | Distance from bottle neck According request |
| Filling Valve | Each filling valve is controled by servo motor ,realizing segmented high-and low-speed control ; vacuum resorption devices without leakage. | |||
| Cap closing method | applicability for both crowning and capping, mechanical instant sealing or servocontrolled sealing | |||
| Bottle components | rapid replacement without tools, such as star wheels for bottle infeed and outfeed, and bottleneck clamps | |||
| Filling precision | limit deviation: ±2-3g standard deviation: 1.5 | |||
| User Ambient Conditions | Temperature:10~40ºC;Humidity:No dew | |||
| User Electrical Supply Specification | Voltage:380V±5%, 3phase; Frequency:50HZ±1% | |||
The High-Capacity Gel Filling & Mixing System is a specialized solution designed for producing alcohol-based hand sanitizers, disinfectant gels, and medical-grade disinfectants in 600ml plastic bottles. Engineered to handle high-viscosity materials (10,000–50,000 cP), this integrated system combines precise mixing, homogenization, and piston filling, ensuring consistent gel quality, accurate fill volumes, and compliance with strict hygiene standards. Ideal for pharmaceutical, personal care, and household chemical manufacturers, it supports end-to-end production from raw material blending to final bottle packaging.
Dual-Function Mixing & Filling:
Mixing Module: High-shear homogenizer (3,000 RPM) with dual-stage rotor-stator ensures uniform gel consistency (viscosity variation ≤5%), capable of blending alcohol, thickeners, and antimicrobial agents.
Filling Module: Servo-piston fillers with heated manifolds (30–50°C) achieve fill accuracy within ±1% of target volume (600ml ±6g), critical for costly formulations containing aloe vera or glycerin.
High-Viscosity Handling:
Auger-feed nozzles with anti-suction technology prevent drip residue (≤0.2g/bottle), while positive displacement pumps maintain steady flow rates for gels up to 50,000 cP.
Automatic viscosity compensation adjusts filling speed in real-time, reducing cycle time by 20% compared to standard piston fillers.
Sanitary Design & Compliance:
316L stainless steel contact parts and FDA-compliant seals, with quick-release mix tank (CIP/SIP capable) for 30-minute sanitization cycles, meeting EU Cosmetics Regulation (EC 1223/2009) and NSF 3-A standards.
Explosion-proof motors and static-dissipative surfaces comply with ATEX/IECEx for flammable alcohol blends (ethanol content ≥60%).
Intelligent Control System:
PLC-based HMI with recipe management stores 100+ formulations (gel density, fill volume, mixing time), enabling 15-minute changeovers between sanitizer and lotion production.
In-line viscosity sensor and load cell feedback ensure real-time quality control, generating traceable reports for GMP and ISO 22716 audits.
Ideal for producing viscous hygiene products:
Personal Care: 600ml HDPE bottles for hand sanitizer gels with aloe vera, supporting pump dispensers and flip-top caps.
Pharmaceuticals: Medical-grade disinfectant gels for hospital use, with optional nitrogen flushing to extend shelf life by reducing oxidation.
Household Cleaning: Large-format gel bottles for multi-surface disinfectants, compatible with embossed HDPE and PET containers.
The system integrates with upstream raw material storage and downstream labeling/packing lines, forming a seamless production ecosystem for high-viscosity liquids.
Q: Can this system handle alcohol concentrations above 80%?
A: Yes, the explosion-proof design and stainless steel construction are certified for ethanol concentrations up to 95%, with nitrogen purge optional for oxygen-sensitive formulas.
Q: What is the minimum batch size for mixing?
A: The mix tank supports batches from 50L to 1,000L, ideal for both small-scale R&D and large production runs.
Q: How is gel consistency monitored during filling?
A: An in-line viscometer measures real-time viscosity, triggering automatic adjustments to filling pressure and speed to maintain uniform flow.
Q: Are custom nozzle designs available for foam sanitizers?
A: Yes, our engineering team can design specialized nozzles for foaming agents, ensuring consistent output for hybrid gel-foam formulations.
| Final Products | |
| Detergents & Corrosive Liquid. Suitable : detergent, shampoo, dishwasher, liquid soap, bleach, clorox, toilet cleaner .etc Bottle Material : PE PP Bottle Bottle Type : Round / Square / Unique Cap : Screw cap Label : Sticker Label |
| Containers and Specifications | ||||
| Project Name: Full-automatic Viscous Liquid Filling Machine | Oil and Fat Products / Daily Chemicals / Corrosive Liquid | |||
| Bottle Material | Bottle Shape | Filling Range | Capacity | Filling level (mm) |
| PET / PP / PE / Glass / Metal | Round / Square / Unique Shape | 200ml-30L | As request | Distance from bottle neck According request |
| Filling Valve | Each filling valve is controled by servo motor ,realizing segmented high-and low-speed control ; vacuum resorption devices without leakage. | |||
| Cap closing method | applicability for both crowning and capping, mechanical instant sealing or servocontrolled sealing | |||
| Bottle components | rapid replacement without tools, such as star wheels for bottle infeed and outfeed, and bottleneck clamps | |||
| Filling precision | limit deviation: ±2-3g standard deviation: 1.5 | |||
| User Ambient Conditions | Temperature:10~40ºC;Humidity:No dew | |||
| User Electrical Supply Specification | Voltage:380V±5%, 3phase; Frequency:50HZ±1% | |||
