5-Gallon Drum Filling Line Operation Manual

Introduction

The 5-gallon drum filling machine integrates the functions of rinsing, filling, and capping into one unit. It is an ideal equipment for the production of mineral water, distilled water, and purified water. The machine is constructed using high-quality stainless steel, which is corrosion-resistant and easy to clean. The electrical circuit system employs branded components. This machine is compact, occupies a small floor space, and offers high and stable working efficiency. It is highly automated and serves as a fully automatic filling equipment combining mechanical, electrical, and electronic elements.

Main Technical Parameters

• (1) Number of Filling Heads: 2
• (2) Filling Capacity: 5 gallons
• (3) Drum Dimensions: 270×490
• (4) Production Capacity: 300 drums/hour
• (5) Power Supply: 380V, 50Hz, Maximum Power Consumption 11KW (Intermittently started by each electrical unit, normal working consumption is only 4KW)
• (6) Water Usage: Drinking water, steam t/h (Filling 18.9 gallons, rinsing 0.1 gallons)
• (7) Air Supply: Pressure 0.45-0.6Npa, Air Consumption 80 liters/minute.

Equipment Installation

This equipment does not require pre-embedded screws in the ground. After unpacking, place the entire machine on a solid and level surface. Adjust the screw height and use a level to correct any tilt to ensure even weight distribution among the support legs. Once the equipment is properly adjusted, connect the water inlet pipe, drain pipe, power supply, air supply, and secure them.

Working Process

The drum filling line can be divided into three main steps: rinsing, filling, and capping. The working process is as follows:

(1) Empty drums are placed on the drum holders. As the chain moves, the empty drums are inverted for mouth and body rinsing.

(2) The rinsing process consists of 7 steps: clean water, disinfectant, sterile water (for mineral water), followed by a 15-second interval for drip drainage.

(3) Cleaned drums are moved down the chain and are flipped upright by the top drum cylinder, placing them in the filling position.

(4) Filling valves extend into the drum mouth, automatically vent, and then open for filling. The filling time is set by the PLC and can be adjusted using the panel's multifunction buttons to achieve the desired level. Excess water is automatically returned to the pure water tank to reduce wastage.

(5) After filling, the filled drums are conveyed to the capping station where they are capped, completing the entire production process.

Use and Operation

(1) Before starting the machine, check the disinfectant level, power supply, and air pressure to ensure they are normal. Manually inspect the solenoid valves, cylinders, water pump directions, and ensure there is no airlock. In case of abnormalities, troubleshoot and resolve before proceeding with production.

(2) The machine operates fully automatically for rinsing, disinfection, filling, capping, and requires no manual intervention. However, operators should closely monitor all components to prevent accidents. In case of chain misalignment, use manual mode to extend the main spindle and adjust the chain to its correct position.

(3) After production, drain any remaining fluids from the pipelines, disconnect the air and water sources, and turn off the power.

Panel Functions

• Power Indicator
• Rinse and Disinfect
• Internal Wash and Fill
• Cap
• Manual/Automatic
• Control Power
• Main Spindle
• Top Drum
• Filling and Capping
• Drum Ejection

For detailed instructions on the panel functions, refer to the manual.

Maintenance and Precautions

(1) Do not alter the parameters in the PLC program as they are already set appropriately at the factory.

(2) Drain the water cup of the pneumatic board's pressure regulating valve assembly daily. Apply low-viscosity machine oil regularly to the mist lubricator to extend the cylinder's lifespan.

(3) The throttle valves of all cylinders are properly adjusted before leaving the factory.

(4) Ensure the air supply pressure is between 0.45-0.6Mpa before starting the production line; otherwise, the system will not function correctly.

(5) When shutting down the equipment, turn off the power switch first, followed by the air supply.

(6) Ensure proper grounding of the electrical system to prevent external interference that may cause misoperation.

(7) Regularly apply lubricating grease to the gears.

(8) Frequently adjust the chain's tension.

HZM Machinery, your trusted manufacturer of 5-gallon filling machines! We are dedicated to designing and manufacturing high-quality, high-efficiency 5-gallon filling machines, providing outstanding solutions for the production of beverages such as mineral water, distilled water, and purified water. Our equipment is constructed using premium stainless steel materials to ensure durability and corrosion resistance while offering high levels of automation, stability, and reliability. Choosing HZM Machinery is a wise decision to enhance production efficiency, ensure product quality, and reduce operational costs. Let's work together to achieve success!

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