For this customer, the goal was to implement a reliable, fully automated filling and capping system for liquid hand soap, capable of integrating seamlessly into an existing production line while maintaining consistent dosing accuracy. The system also needed to meet the specific safety requirements of a potentially explosive production environment and support efficient cleaning and maintenance.
The challenge
The customer was looking for a filling solution that could combine high dosing accuracy with production flexibility. The system needed to handle different bottle sizes and closures, reduce downtime during format changes and ensure safe, repeatable operation when processing chemical products.
At the same time, filling performance had to remain stable despite variables such as product temperature and line speed. This called for precise weight control combined with a feeding system capable of handling the product efficiently, while keeping product hold-up to a minimum.
The Weightpack solution
Weightpack supplied a fully automatic monoblock system integrating net weight filling and rotary capping, specifically configured for liquid hand soap.
The filling process is based on individual weight control. Each container is monitored through the tare, filling and final check stages by IP69K load cells, allowing the system to continuously verify filling accuracy and automatically correct deviations.
The tankless product feeding system uses a brushless-driven positive displacement pump, making it suitable for high-viscosity liquids while keeping product hold-up below 15 litres. Automatic compensation further adjusts the filling process according to variables such as temperature and line speed, helping maintain consistent performance throughout production.
The solution also includes:
- Filling accuracy of up to ±0.5 g, supporting precise and repeatable dosing.
- Fast, tool-less format changeovers, minimizing downtime between production runs.
- ATEX-compliant configuration for operation in potentially explosive atmospheres.
- Rotary capping with magnetically controlled heads, with adjustable torque for different closure requirements.
- Intelligent reject management, supporting continuous quality control.
- CIP-ready construction, with AISI 316L stainless steel used for all product-contact parts.
Performance in production
The result is a compact, highly automated system that gives the customer precise control over filling while maintaining the flexibility required for a demanding production environment.
By combining real-time weight control, automatic correction and fast format changeovers, the system helps maintain consistent product quality while reducing production downtime. The tankless configuration also limits product hold-up, helping to reduce product waste, while the cleanable design supports efficient maintenance and hygiene management.
For the customer, the solution brings precision, flexibility and operational safety together in a single reliable system, supporting efficient and consistent production of liquid hand soap.