In the case of pouch packaging we see that liquid spills are a large issue. While a little bit of product may0.9 that which is put out at filling may be considered a minor issue it grows into a large problem when it is repeated. This results in waste of product, messy equipment, longer clean up times, and inconsistent packaging.

In many cases the issue becomes more apparent when it is the manufacturers of sauces, beverages, dairy alternatives, gels, detergents, lotions and other liquid or semi-liquid products which report it. We see that different products perform in diverse ways during fill which in turn requires the packaging process to match the product’s flow and the pouch format.

A right set up Liquid Packaging Machine is able to control the fill process which includes product dosing, pouch positioning, filling and sealing. For spouted pouches a Spout Pouch Filling Machine also takes care of the fill via the pouch spout which is then sealed or capped.

So what is the cause of liquid spills and what can be done to reduce them via better pouch filling?

Why do we get liquid spills in pouch filling?

Liquid spillage is a result of multiple issues. At each stage of the packaging process there is a chance of product leakage or overflow.

Common causes include:.

• Incorrect filling volume
• Filling too quickly
• Product dripping from the filling nozzle
• Poor pouch positioning
• Incorrect filling height
• Product foaming during filling
• Differences in product viscosity
• Improper sealing
• Incorrect machine settings
• Damaged or unsuitable pouches

Identifying the cause is the first step to reducing spills.

How Can a Liquid Packaging Machine Reduce Spills?

A Liquid Filling Machine does better at consistent performance than manual filling. Instead of having a person estimate the quantity and place the product the machine uses a set filling cycle.

In some machines we have:.

1. Pouch loading
2. Pouch opening or positioning
3. Liquid filling
4. Filling completion
5. Pouch handling
6. Sealing or capping
7. Finished pouch discharge

Each step must be performed right for the package to stay clean and sealed.

Does Filling Speed Affect Liquid Spills?

Yes. Filling rate affects how the product performs in the pouch.

If a liquid is poured in too fast it will splash, foam, or run to the top of the pouch. This is an issue with products which have low viscosity or which contain foaming agents.

Also at issue is that which causes production output to drop.

The aim is to use a fill rate which matches the product and pouch type. Machine settings do which can include:.

• Product viscosity
• Fill volume
• Pouch size
• Product temperature
• Pouch design
• Filling system
• Required production speed

Testing out various settings will identify what works best for production speed and clean filling.

Why Does Product Viscosity Matter?

Some liquids don’t behave the same.

Water, juice, cooking oil, sauce, syrup, lotion, and gel present a wide range of flow characteristics. A thin liquid will pass through a filling system quickly, at which point a different approach may be required for a thicker product.

This is the reason for choosing the appropriate product.

A design to best put out the right amount and time of liquid into the bag is a feature of quality packaging machines.

For thicker products we have machines that require a filling system which is able to handle higher viscosity and at the same time avoid inconsistent fills or excessive drip.

How Does a Spout Pouch Filling Machine Help?

A Spouted Pouch Filling Machine which is designed to meet the needs of spouted packaging.

Instead of filling via a large opening in the bottom of the bag we put in the product through the bag’s spout. Also the machine is able to handle all things related to the bag  from handling, to filling, to spout related tasks based on its setup.

This is true for products like:.

• Sauces
• Juices
• Liquid foods
• Purees
• Dairy alternatives
• Gels
• Detergents
• Lotions
• Other liquid and semi-liquid products

Spout included in pouches also provides a convenient solution for customers to pour out or dispense the product upon opening.

Can Incorrect Pouch Positioning Cause Spills?

Yes. Pouch placement is key in automatic filling.

If the pouch does not go into the fill station in the right way the product may end up in the wrong place. This may cause product splash, contamination of product around the pouch top, or inconsistent fill.

During the fill cycle the pouch should be stable. Also it is a function of the automated pouch handling systems to maintain the same position throughout the process.

In the case of spouted pouches precise positioning is very important as the filling system has to align with the spout.

How Can Nozzle Dripping Create Packaging Problems?

After completion of the fill cycle some liquid may remain in the nozzle which is an issue.

Dripping may:.

• Make the pouch exterior messy
• Waste product
• Contaminate sealing areas
• Increase cleaning requirements
• Affect package appearance

The right filling system must be used for the product which is to be packaged. Also machine settings and filling components play a role in how the product comes out of the nozzle.

Products that have different viscosities may require different filling methods.

What Happens If Liquid Reaches the Sealing Area?

Liquid intrusion near the seal may affect package integrity.

When the sealing point product is in between the pouch layers the seal may not form properly. This increases the risk of leakage post packaging.

A proper filling process which is controlled helps keep the product away from the intended sealing area.

This is true in high speed packaging which at the time of issue may be replicated across many pouches.

How Can Better Sealing Reduce Leakage?

Filling is but one aspect of liquid pouch packaging. Also the seal must be right.

In some machines and pouch types sealing parameters which may include:.

• Sealing temperature
• Sealing pressure
• Sealing time
• Pouch positioning
• Seal area cleanliness

Correct settings which depend on the pouch material and packaging format.

In the case of spouted pouches what we see is that the spout and cap or closure play a key role in the security of the final package.

Can Foaming Cause Liquid Spills?

Yes. Some products that are in liquid form may produce foam at the time of filling.

Foam in the pouch takes up space which in turn may not allow for a consistent fill. Also if the product foams greatly at the top of the pouch it may complicate the sealing process.

The filling process is to be adapted to the product’s foaming behavior. We also use a proper filling system to control the rate at which the product is filled.

How Can You Reduce Liquid Waste During Packaging?

Reduction of spills comes from first identifying where the product is going out.

Manufacturers can review:.

Filling Accuracy

Check if each pouch has the right amount. Inconsistent fill levels may indicate a need to adjust the filling system.

Filling Speed

Compare performance of flow rate with that of the product’s viscosity and behavior. While faster may be ideal in some cases it may also cause splashing or foaming.

Pouch Position

Make certain the pouch is in the right place during filling.

Nozzle Performance

Check after each cycle for the filling nozzle.

Seal Area

Check if the product is going to the sealing area before the pouch is closed.

Pouch Quality

The pouch should fit the filling and sealing process.

These issues can be determined by which machine, product, pouch, or machine setting is at fault.

What Products Can Be Packed Using a Liquid Packaging Machine?

Liquid packaging machines are used for a wide range of products which is determined by the fillers and machine setup.

Examples include:.

• Juices
• Sauces
• Ketchup
• Mustard
• Syrups
• Dairy alternatives
• Purees
• Liquid foods
• Gels
• Lotions
• Detergents
• Other thin or viscous liquids

The key is to match machines to the products instead of whichever filling system we think will do at any given time.

How Does the RS-4 Handle Spouted Pouch Filling?

Unified Flex’s RS-4 Spouted Pouch Filler and Capper we have that they put together for spouted pouch applications. As per the info given out by the machine manufacturers it is able to handle fill volumes which range from 20 ml to 2,000 ml and also reported to achieve run rates of up to 80 pouches per minute which varies by what the application and machine setup is.

The machine is built for thin and viscous liquid products which is to say it does sauces, juices, dairy alternatives, gels, lotions, and detergents.

It is the full scale solution that combines many packaging processes into one machine for spouted pouches.

What Should You Check When Choosing a Liquid Packaging Machine?

If in your packaging process you are already experiencing issues with spills, machine choice should go beyond production speed.

Consider:.

Product Type

Determine the consistency of your product: is it thin, medium, thick, sticky, foamy or does it present some other filling issue?

Fill Range

Check the output range for each pouch.

Pouch Format

Determine what type of package you are using, standard, stand up or spouted.

Production Requirements

Consider the number of bags or pouches per minute that you will be able to produce instead of which is the machine's max rated speed.

Sealing or Capping

For spouted packages check how the machine performs with the spout and closure.

Cleaning Requirements

Liquid products may leave behind residue in fillers. Therefore equipment has to meet the specific cleaning requirements of the product.

Can Automation Completely Eliminate Liquid Spills?

No packaging machine is perfect in preventing spills. Product behavior, pouch quality, machine settings, fill components, and operating conditions play a role.

Also we see that automation improves the consistency of the fill cycle and also reduces issues related to manual fill.

The best way is to tailor the machine and filling system to the product, pouch format, fill volume, and production needs.

Final Thoughts

Liquid discharge during packaging may be from a number of causes which include high fill speed, incorrect fill volumes, nozzles which are leaking, poor placement of the pouch, foaming, defective filling equipment, or issues related to the sealing area.

A properly set up Liquid Packaging Machine can provide better consistency in fill and pouch handling. For spouted pouch applications a Spout Pouch Filling Machine can integrate fill through the pouch spout with other packaging processes.

Before choosing equipment manufacturers should take into account the liquid’s viscosity, fill volume, pouch format, production speed, sealing or capping requirements, and cleaning issues.

The aim is not just to speed up the filling process. We want to have a controlled environment which puts out the right quantity into the bags and at the same time keeps the filling area, the pouch and the sealing process free of trouble and variation.

Frequently Asked Questions

Why do packages leak during fill?

Spills are a result of excessive fill speed, incorrect fill volume, product foaming, nozzle dripping, poor pouch placement, or machine settings that do not match the product.

Can thick liquids be handled by a Liquid Packaging Machine?

Sure, with regard to machine and filling equipment. Thick products require gear that is able to handle their viscosity and flow properties.

What does a Spout Pouch Filling Machine do?

A Spout filled Pouch Machine we put to use for filling in to spouts which are in the pouches. Also based on the design of the machine it may include spout capping and other packaging features.

What is the best way to reduce liquid waste in pouch filling?

Start with evaluating fill accuracy, fill speed, nozzle leakage, pouch placement, product foaming, and seal performance. Also it is important to match the filling system to the product.

Which products are for spouted pouches?

Spouted containers which include pouches are used for products like sauces, juices, purees, dairy alternatives, gels, lotions, detergents and also other liquid or semi-liquid products.

Does pouch sealing affect liquid leakage?

Yes. In some cases packages may be contaminated at the seal area which in turn may be a result of improper sealing parameters that in large scale can break the package closure and increase risk of leakage.

What to look for when you are purchasing a liquid packaging machine?

At the design stage think through product viscosity, fill volume, pouch format, production requirements, filling system, sealing or capping process, and cleaning requirements before which to choose.