How to Choose the Right Filling Machine: Liquid Types, Pumps, and Customized Solutions

What is a Liquid Filling Machine?

A liquid filling machine—also known as bottle filler or liquid packaging equipment—is a type of industrial machinery designed to accurately dispense liquid products into containers such as bottles, jars, or pouches. Whether the product is water, juice, oil, detergent, or lotion, the goal of a filling machine is to ensure:

Precision: Delivering the correct volume every time

Speed: Improving production efficiency and throughput

Hygiene: Meeting sanitary standards for food, cosmetics, or pharmaceuticals

Consistency: Maintaining product quality and reducing waste

These machines are used across multiple industries including food & beverage, cosmetics, pharmaceuticals, and chemicals. Depending on the product's characteristics—like viscosity, foaminess, or particle content—different pump types and machine configurations are selected.

When it comes to filling products into bottles, pouches, or containers, choosing the right filling machine is more than just matching capacity. It's about understanding the type of liquid, filling speed, accuracy, and the right pump for the job.

At ZONESUN, we help global manufacturers customize high-performance liquid filling equipment tailored to their product characteristics and production scale. This guide walks you through the essential classifications and real-world cases to help you make the best choice.

Classifying Liquids for Filling Machines

Different liquids require different filling strategies. Based on flow characteristics, liquids can be divided into:

➤ Free-flowing Liquids

Examples: Water, mineral water, juice: Best with gravity pumps or diaphragm pump

➤ Viscous Liquids

Examples: Detergents, lotions, honey, syrup: Require piston pumps or rotary lobe pumps

➤ Liquids with Solids

Examples: Juice with pulp, soups, sauces: Ideal for rotary lobe pumps (gentle handling)

➤ Foamy or Volatile Liquids

Examples: Shampoo, sanitizer, products with alcohol: Recommended: diaphragm pumps, gear pumps, or EX-proof fillers

Selecting the Right Pump Type

Choosing the proper filling pump is key to achieving accuracy, speed, and product integrity. Here’s a breakdown:

Pump Type	Ideal Applications	Features
Piston Pump	Creams, sauces, viscous liquids	High precision, volume-based filling
Peristaltic Pump	Pharma, essential oils, cleanroom filling	Sterile, no contamination risk
Gear Pump	Low to medium viscosity liquids	Constant flow, compact design
Diaphragm Pump	Foamy, corrosive, or flammable liquids	No seals, good for alcohol-based products
Rotary Lobe Pump	Chunky liquids with solids	Gentle handling, ideal for fruit juices or pulps
Gravity Pump	Thin, free-flowing liquids	Cost-effective, simple maintenance
Auger Pump	Powders, granules	Used in dry product filling machines like soy powder

Product Categories and Matching Machines

✔ Beverages:

Water, juice, wine — require accurate, hygienic filling. Recommended: Gravity or gear pump filling machines

✔ Cosmetics & Personal Care:

Lotions, essential oils, shampoos — demand precision and clean design. Recommended: Piston or peristaltic pump machines

✔ Chemicals & Cleaning Products:

Acids, alcohol-based sanitizers, detergents — require safe and stable operation. Recommended: Diaphragm or EX-proof gear pump machines

✔ Food with Particles:

Jam, sauces, juice with pulp — careful handling of solids is necessary. Recommended: Rotary lobe pump fillers

✔ Powder Products:

Milk powder, protein mix, flour — need dust-free and precise filling. Recommended: Auger filling machines with vertical form-fill-seal (VFFS)

Customization Options: Build Your Ideal Machine

At ZONESUN, we provide customized solutions to match your production needs:

Filling Heads: Single, double, or multi-head configurations

Speed Requirements: Adjustable output from 10–100 bottles per minute

Combo Integration:

• Filling + Capping Machines (liquid bottle lines)Filling + Sealing Machines (VFFS for pouches or sachets)

Automated Line Integration: Connect bottle washers, cappers, conveyors, and labeling machines to form a fully automated packaging line

Real-World Applications and Solutions

Case 1: Juice with Pulp in Glass Bottles (300ml, 17–20 BPM)

• Challenge: Pulp may clog nozzles or be crushed
• Solution: Use a rotary lobe pump for gentle handling
• Recommended Machine: ZONESUN automatic filling machine with 4 filling heads and anti-drip nozzles
• Result: Smooth production with accurate filling and no pulp damage

Case 2: Bottled Mineral Water (50 BPM)

• Challenge: High speed, free-flowing liquid
• Solution: Simple gravity pump system for reliable output
• Recommended Machine: Linear gravity filler with integrated capper and labeler
• Result: Affordable, high-efficiency bottling line

Case 3: Soy Milk Powder in Small Sachets (80×60mm)

• Challenge: Small pouch size and powdery texture
• Solution: Use an auger filler with a VFFS machine
• Recommended Machine: ZONESUN automatic vertical packaging machine with dust-proof auger system
• Result: Clean, accurate, and efficient sachet filling

Case 4: Detergent with Alcohol Content (250ml, 1500 BPH)

• Challenge: Potentially explosive, flammable ingredients
• Solution: Use a gear or diaphragm pump with explosion-proof housing
• Recommended Machine: Flame-proof ZONESUN liquid filling machine with stainless steel frame
• Result: Safe and compliant production environment

About ZONESUN Filling Machines

ZONESUN is a leading manufacturer of intelligent packaging equipment. With over a decade of experience in the industry, we specialize in:

Customized filling machines for liquids, creams, powders, and pastes

Complete turnkey packaging lines

Flexible OEM/ODM services

Global delivery and support

From small startups to large-scale factories, our ZONESUN filling machines are used by thousands of clients worldwide to improve efficiency and product consistency.

Frequently Asked Questions (FAQ)

Q1: How do I know which filling machine suits my product?
We recommend starting with liquid type, container size, and required speed. Contact our team for expert advice.

Q2: Can ZONESUN machines fill both liquid and powder?
Yes, we offer combo and modular machines with interchangeable filling systems.

Q3: What if I need automation in my production line?
We provide full automation solutions including washing, filling, capping, labeling, and even palletizing.

Q4: Is the equipment food-grade certified?
Absolutely. All contact parts use SUS 304/316 stainless steel and comply with food safety standards.

Q5: Can you ship internationally?
Yes. We serve clients across North America, Europe, Southeast Asia, and the Middle East.