The fully automatic tube filling and hot air sealing machine is designed to handle precise filling and sealing operations for soft tubes in industries such as cosmetics, pharmaceuticals, food, and chemicals. This high-performance equipment automates the process from tube feeding, filling, hot air sealing, and trimming, to product ejection, ensuring efficiency and quality in each step.
Key Features and Functionalities:
Automatic Tube Feeding: Equipped with an intelligent tube sorting and feeding system, the machine automatically loads tubes into the designated holders, streamlining the setup process for high-speed production lines. It supports various tube materials, including plastic, laminated, and metal tubes.
Accurate Dosing and Filling System: The filling unit is driven by a precision pneumatic system, offering adjustable dosing volumes with high accuracy (up to ±0.5%). It accommodates a wide range of viscosities, making it suitable for creams, gels, pastes, and other semi-viscous products.
Hot Air Sealing Technology: Utilizing advanced hot air sealing technology, the machine ensures airtight and aesthetically pleasing seals on each tube. The hot air system heats the interior of the tube, melting the plastic and providing a strong, durable seal without compromising the product’s integrity.
Tail Trimming and Coding Options: Post-sealing, the machine automatically trims excess material for a neat, consistent appearance. It also includes options for embossing or inkjet printing codes, dates, or batch numbers on the tube, ensuring traceability and compliance with industry standards.
User-Friendly Control System: The machine is operated via a modern PLC with a touch-screen interface, allowing operators to adjust filling volume, sealing temperature, and production speed easily. The system includes memory functions for different product specifications, allowing quick and efficient changeovers.
Precision Tube Alignment and Positioning: With photoelectric sensors and automated tube orientation, the machine ensures that each tube is correctly positioned before filling and sealing, reducing waste and enhancing output quality.
Hygienic, Durable Construction: Constructed from stainless steel and corrosion-resistant materials, the machine adheres to GMP and FDA standards for hygiene and safety, making it ideal for sensitive products. Its design is easy to clean and maintain, minimizing downtime and maximizing operational efficiency.
Safety and Fault Detection: The machine includes multiple safety features such as overload protection, emergency stop functions, and automatic fault detection systems. In the event of a fault, the machine pauses and displays the issue on the control panel, allowing operators to address it promptly.
Application and Benefits:
This fully automatic tube filling and hot air sealing machine is ideal for large-scale production facilities where efficiency, accuracy, and product integrity are crucial. By automating the entire process, it reduces labor costs, minimizes product waste, and ensures consistent, high-quality output with every cycle. The machine is versatile enough to handle a variety of tube sizes and fill materials, providing exceptional flexibility to meet diverse production needs.
Parameter
| Tube type: Plastic tube, Multiple tube |
| Filling range: A.6-60ml, B.10-120ml, C.25-250ml, D.50-500ml |
| Sealing type: Heating sealing |
| Capacity: 1800-4200 tubes/hour |
| Number of work positions: 12 |
| Safety protection: overload protection |
| Filling nozzle: Anti-drop |
| Filling accuracy: ±1% |
| Sealing shape: Flat tail, curved tail, special-shaped tail |
| Applicable tube diameter: 12-50mm |
| Applicable tube height: 50-250mm |
| Automatic detection function: No work without tube |
| Tube loding: Automatic |
| Air pressure: 0.6-0.7Mpa |
| Air comsumption: 0.3m3/min |
| Power: 3KW |
| Voltage: 380V/50Hz |
| Air consumption: 1-3m³/min |
| Machine size: 2600×1250×1980mm |
| Machine weight: 1100kgs |
| Touch screen: Mitsubishi |
| PLC: Mitsubishi |
| Sensor: Banner/OMRON/Panasonic |
| Inverter: Mitsubishi |
| Heater: (400F ) SWITZERLAND |
| Temperature controller: (400F ) DELTA |
| Pneumatic components: AirTac Taiwan |
| Electrical components: Delixi, CHNT, Schneider |
Rotary Worktable
This rotary worktable system integrates multiple processes into a streamlined, automated workflow, including:
Tube Feeding: Automated placement of tubes onto the worktable.
Positioning: Precise alignment of tubes for accurate processing.
Filling: Dispenses product into tubes with precise volume control.
Heating: Utilizes hot air for pre-heating the tube ends for sealing.
Sealing: Ensures secure, airtight sealing of tube ends.
Coding: Applies batch codes or production information onto the tube.
Cutting: Trims excess material from the tube end post-sealing.
Ejection: Releases finished tubes from the worktable for collection.
1. Tube Feeding
The Tube Feeding system automates the process of placing empty tubes onto the worktable. Equipped with a tube sorting mechanism, this system ensures each tube is positioned upright and in the correct alignment for subsequent processing. It increases production efficiency by reducing manual handling, providing a smooth workflow for high-speed operations.
2. Positioning
The Positioning mechanism utilizes sensors to accurately align each tube before filling. This guarantees precise label or seam alignment, ensuring that each tube is correctly positioned for the filling, sealing, and coding stages. This process minimizes errors, reduces material waste, and ensures uniform output quality.
3. Filling
The Filling system is designed to handle a variety of product consistencies, from liquids to thick creams. With precise volumetric controls, the filling nozzle dispenses the exact amount of product required, reducing overfill or underfill. It supports a range of filling volumes to meet various production needs and ensure consistent, accurate filling every time.
4. Heating
The Heating unit uses hot air technology to pre-heat the open end of each tube before sealing. This step is critical for melting and softening the tube’s plastic, preparing it for a strong, airtight seal. This system maintains a consistent temperature to ensure optimal bonding without damaging the tube material.
5. Sealing & Coding
The Sealing mechanism compresses the heated tube ends, creating a tight and durable seal. This ensures that the product is securely contained within the tube, preventing leaks and preserving product integrity. The sealed edges are smooth and professional, meeting quality standards across industries.
The Coding unit applies batch numbers, expiration dates, or other important information directly onto each tube. This can be done via embossing. Coding ensures product traceability and regulatory compliance, providing essential information for quality control.
6. Cutting
The Cutting system trims excess material from the sealed end of each tube, providing a neat, uniform appearance. This process enhances the final presentation of the product while ensuring that all tubes have a consistent, professional finish, ready for retail packaging.
7. Ejection
The Ejection mechanism safely releases the processed tube from the worktable into a collection bin. This automated ejection ensures that each tube is promptly removed after processing, allowing for uninterrupted operation and reducing manual handling. It maximizes output and maintains a smooth production line.
Touch Screen
The Touch Screen interface offers a user-friendly control panel where operators can monitor and adjust machine settings, including speed, volume, temperature, and coding parameters. It also features error detection and diagnostic functions, allowing operators to quickly troubleshoot and maintain optimal machine performance.
Electric Box
The Electric Box houses all of the machine’s electrical components, including circuitry and safety switches. Designed for easy access and maintenance, this box ensures stable power supply and controls the machine’s automation functions. It is equipped with protective features to prevent overload and ensure operator safety.
Material Feeder & Chiller
The Material Feeder provides a steady supply of product material directly to the filling system, ensuring continuous operation and reducing manual refilling needs. With adjustable flow control and a high-capacity hopper, the feeder maintains a consistent supply regardless of material viscosity, from thin liquids to thick pastes. The hopper is designed to minimize material wastage and includes anti-clogging features, guaranteeing smooth, uninterrupted operation during long production runs. The material feeder is also easy to clean, supporting fast changeovers between different products.
The Chiller, or cold water machine, is specifically designed to protect soft tubes from overheating during high-temperature sealing and filling processes. By circulating chilled water around the tubes, the chiller maintains a consistent, low temperature on the exterior surfaces, effectively preventing the soft material from deforming or melting. This precise cooling system is essential for preserving tube integrity and ensuring that the sealing process produces clean, undamaged finishes.
Transmission System
The Transmission System is a crucial component that powers the coordinated movement of the machine’s various stages, including tube feeding, positioning, filling, sealing, and ejection. It operates using precision-engineered gears, belts, and motors to ensure smooth, synchronized motion across all sections of the production line. This system enables accurate timing and alignment of each stage, allowing the machine to operate at high speeds without sacrificing precision.
Built for durability and stability, the transmission system uses high-quality materials and a robust design to withstand long production cycles and heavy-duty operation. With minimal vibration and noise, it ensures steady performance and reduces wear on other machine parts, extending the overall lifespan of the equipment. Additionally, the transmission system includes adjustable speed controls, enabling operators to customize operational speed based on production requirements, enhancing flexibility and efficiency across different product runs.
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