Introduction to the Vormek Mechoris Liquid VFL-510
The gravity filler is one of the most economical and reliable filling methods for products with low viscosity that flow naturally under gravitational force. Due to its simple operation, easy cleanability, good accuracy, and low maintenance cost, this technology has become one of the most widely used filling systems across various industries.
The Mechoris Liquid VFL-510 is a gravity filler that transfers product from the tank to the container using gravity. In this system, product flows from the tank to the nozzles without the need for high-pressure pumps or complex equipment, and is discharged into containers. This technology is suitable for products with sufficient fluidity to move naturally through pipes and nozzles.
In the food, dairy, pharmaceutical, and chemical industries, low-viscosity products—such as water, doogh (yogurt drink), fermented beverages, herbal distillates, vinegar, lemon juice, pharmaceutical solutions, and oral serums—require specialized filling technology due to their high fluidity, fast flow behavior, and sensitivity to contamination.
Types of Gravity Fillers
Standalone Gravity Filler
In this configuration, the filling system is installed independently alongside the packaging machine.
Advantages:
- Larger tank capacity
- Easy access for service and maintenance
- Ability to increase the number of nozzles
- Suitable for high-capacity production lines
This model is typically used in large factories and high-capacity industrial lines.
Gravity Filler Mounted on Packaging Machine
In this configuration, the tank and filling assembly are mounted directly onto the packaging machine.
Advantages:
- Compact design
- Minimal production floor space
- Shorter product transfer path
- Suitable for workshops and factories with space constraints
Importance of Tank Type Selection
One of the key components of any gravity filler is the product storage tank. Depending on the product type, the tank can be designed in two ways:
Single‑Wall Tank
For products filled at ambient temperature with no thermal control requirements.
Double‑Wall (Jacketed) Tank
For many food products, the product must be filled at a specific temperature. In such cases, a double-wall tank is used. Hot water or thermal fluid circulates between the two walls, maintaining product temperature throughout the production process.
Advantages of Jacketed Tanks:
- Maintains product viscosity
- Prevents quality degradation
- Prevents product cooling
- Increases filling process stability
Agitator System – Ensuring Product Uniformity
Some food products contain suspended particles that settle at the tank bottom if mixing stops. To prevent this, the filler can be equipped with an agitator system.
Benefits of Using an Agitator:
- Prevents material settling
- Maintains product quality
- Increases filling accuracy
- Ensures product uniformity across all containers
Tank Level Control and Process Stability
The level control system automatically monitors the product level inside the tank, preventing issues such as:
- Tank emptying
- Air ingress into the system
- Product overflow
Product Temperature Control with Thermocouple
For products where filling temperature is critical, temperature sensors are essential. The thermocouple installed on the tank enables continuous temperature monitoring, allowing operators to observe and control process conditions at any time.
Anti‑Drip Nozzles – Eliminating Waste and Contamination
A common problem in filling systems is product dripping after the filling cycle ends. Professional fillers use anti-drip nozzles.
Benefits:
- Prevents product waste
- Maintains clean production environment
- Increases filling accuracy
- Prevents container contamination
Bottom‑Up Filling Technology
Some products foam or form bubbles during filling. To address this, a bottom-up filling system can be used:
Method:
- Nozzle enters the container
- Filling begins from the bottom
- Nozzle rises as the product level increases
Benefits:
- Minimizes foaming
- Prevents bubble formation
- Improves product appearance
- Increases filling accuracy
Common Challenges in Filling Liquid Products
| Challenge | Description |
|---|---|
| Overflow and waste | Rapid liquid flow without precise control leads to overfilling and spillage |
| Bubble and foam formation | High-speed filling creates bubbles affecting actual volume |
| Dripping after filling | Lack of anti-drip nozzles contaminates the environment and adjacent containers |
| Hygiene and cross-contamination | Product-contact parts must be fully washable and sanitizable |
| Container format change | Many machines are designed for specific heights and diameters; changes require time-consuming adjustments |
Volumetric, Time‑Based, or Weight‑Based Filling?
Depending on customer requirements, the gravity filler can be controlled by different methods:
Time‑Based and Flow‑Based Control
The valve opens or closes based on a set time, controlling the amount of product filled into the container.
Load Cell‑Based Weight Control
For applications where final filling accuracy is critical, the load cell system is the optimal choice. Product weight is measured in real-time and sent to the PLC. The PLC then controls the gradual valve to manage flow and ensure precise filling.
Filling Process Options
| Method | Description | Best For |
|---|---|---|
| Load Cell + Control Valve | Containers filled to 90%, then weight-controlled to exact volume | High-value products, accuracy of ±3 g |
| Cylinder and Piston | Volume controlled by positive displacement | Slightly higher viscosity or volumetric accuracy requirements |
| Timer + Flow Control | Filling based on time and constant flow rate | Lower-value products, high speed, moderate accuracy |
Hygienic Design and Compliance
In the food, dairy, and pharmaceutical industries, hygiene is not optional—it is a requirement. The Mechoris Liquid VFL-510 is designed with hygienic engineering principles:
| Hygienic Feature | Description |
|---|---|
| Product-contact materials | 316 stainless steel (resistant to corrosive and acidic substances) |
| Main body | 304 stainless steel (rust-proof, washable with industrial detergents) |
| Anti-drip nozzles | Prevents drips and liquid accumulation on the machine |
| Smooth surfaces, no dead corners | Prevents contamination buildup; fast, effective cleaning |
| Full internal component access | Easy disassembly, cleaning, and sanitization without special tools |
Advantages of Choosing the Mechoris Liquid VFL-510
| # | Reason |
|---|---|
| 1 | Custom design based on customer requirements |
| 2 | Technical expertise of the design team |
| 3 | Quality components and standard automation |
| 4 | Simple and fast cleaning |
| 5 | Access to service and spare parts |
| 6 | Compatibility with existing packaging lines |
Table 1: TCO Analysis – Manual vs. Automatic Gravity Filler
| # | Cost Item | Manual Filling | Automatic Filling with VFL-510 | Savings / Description |
|---|---|---|---|---|
| 1 | Labor (salary + other costs) | Requires 2–3 operators | Requires 1 operator | 73% labor cost reduction |
| 2 | Product waste (scrap) | 5–10% of production volume | Less than 1% | Significant waste reduction due to ±3 g accuracy |
| 3 | Line downtime for cleaning | 2–3 hours per shift | 30–45 minutes per day | Increased effective production time |
| 4 | Cleaning and sanitation cost | Additional labor + time | CIP design + easy access | 50% cost and time reduction |
| 5 | Spare parts and annual repairs | Mostly none (hand tools) | Approx. 3–5% of machine price | Modest cost, offset by reduced downtime |
| 6 | Human errors and product returns | High (weight inconsistency, contamination) | Very low (consistency and high hygiene) | Reduced returns = increased customer trust |
| 7 | Initial investment (CAPEX) | Zero (ongoing monthly expense) | Machine purchase (fixed asset) | ROI typically less than 12 months |
| 8 | Container format change capability | Time-consuming; requires tools | Under 5 minutes; no tools required | Increased line agility |
Table 2: Practical Benefits of Choosing the Gravity Filler
| # | Practical Benefit | Impact on Production | Impact on TCO |
|---|---|---|---|
| 1 | Significantly reduced labor dependency | One operator replaces 2–3 per shift | 73% annual labor cost reduction |
| 2 | Complete cross-contamination prevention | Hygienic design, stainless steel, anti-drip nozzles | Reduced return and hygiene waste risk |
| 3 | Compatibility with a wide range of containers | Quick height and nozzle adjustment without tools | Reduced downtime between orders |
| 4 | Reduced product waste due to precise measurement | ±3 g accuracy, two-stage weighing | Up to 90% waste reduction vs. manual |
| 5 | Fast startup without complex settings | Easy initial setup; recipe storage in PLC | Increased productivity at shift start |
| 6 | Easy cleaning and maintenance | Quick component disassembly and reassembly | Reduced cleaning costs; extended machine life |
| 7 | Quick nozzle changeover | Manual change without tools in under 5 minutes | Reduced downtime; increased line flexibility |
| 8 | Suitable for low to semi-industrial volumes | Scalable from 500 to 5000 units/hour | No additional investment for lower volumes |
| 9 | Customizable configuration | Nozzle count, tank size, control type (load cell/piston/timer) | Reduced excess cost; perfect fit for actual needs |
