Filling Machine Operation Guidelines

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Update:Aug, 25 /2023
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Inspection and Preparation Before Operation:

  1. The on-site operator performs daily pre-start checks and inspections on the equipment based on the "Filling Machine Daily Inspection Checklist," and records the results in the "Production Inspection" section of the checklist.
  2. The electromechanical maintenance worker performs weekly checks and inspections on the equipment according to the "Filling Machine Daily Inspection Checklist," and records the results in the "Electromechanical Inspection" section.
  3. The electromechanical maintenance worker carries out necessary lubrication on the equipment based on the "Filling Machine Lubrication Manual" and records the results in the "Lubrication Record" of the checklist.
  4. A comprehensive 4S (Sort, Set in order, Shine, Standardize) work must be conducted on the equipment before starting up and after production.
  5. Check all pipeline valves for integrity and absence of leaks.
  6. Verify the condition of all instruments and the normal functioning of circuits.
  7. Inspect the normal operation of instrument and circuit moving parts.
  8. Ensure smooth rotation of all moving parts, no blockages, secure fastening, correct rotational direction, and proper lubrication.
  9. Clean the area around the filling machine and any debris on the conveyor belt.
  10. Flush the pipeline of the filling machine with pre-qualified pharmaceutical liquids until the liquid matches the retained sample. Return the flush liquid to the finished product tank.
  11. Open the adsorption device and close the machine room door.

Operating Steps:

  1. Power on and start the air compressor, adjust the pressure to 6 kg/cm², supply compressed air to the filling machine, and connect the power source.
  2. Set the filling specifications and quantity.
  3. Perform manual filling and calibration of filling measurements.
  4. Turn the selector switch to "Manual," press the manual bottle feeding button, release after a set of bottles are loaded and aligned.
  5. Press the manual dosing button to dispense the appropriate amount of material into each bottle, then release the button.
  6. Use the manual bottle discharge button to remove bottles containing material.
  7. Once calibration is confirmed, switch the selector to "Automatic" to initiate sequential bottle entry and discharge for batch production.
  8. During the filling process, every 5-10 minutes, the operator should use an electronic scale to randomly check if the measurements are within acceptable limits.
  9. After shutdown, clean residual materials and impurities from the filling machine pipeline, wipe the conveyor belt, and complete the "Critical Equipment Operation Record."

Key Technical Parameters of Automatic Filling Machine:

  1. Filling Method: Linear intermittent/positioning.
  2. Filling Error: ±0.3% to ±0.5% (for volumes of 250 and above); Power: 0.75KW to 1.5KW.
  3. Output: 2400 to 3000 bottles/hour.
  4. Equipment Specifications: 20ml.
  5. Power: 380v, 1.1kw.
  6. Coil: 220v, 50w.

Maintenance Procedures:

Routine Maintenance:

  1. Clean the machine inside and out daily, ensuring there is no oil residue or dirt, achieving a clean appearance.
  2. Perform pre-shift and post-shift cleaning of the equipment.
  3. Check the sensitivity of photoelectric sensors and the completeness of mechanical parts.
  4. Ensure lubrication points are adequately greased.
  5. Observe the main machine for abnormal noises, vibrations, and odors during operation.
  6. Regular maintenance:
  7. Organize electrical control box wiring and clean any residue inside.
  8. Inspect electrical components for proper contact and grounding to prevent leakage.
  9. Check motor bearings for abnormalities and assess motor insulation.
  10. Verify the flexibility of moving mechanisms, check for severe wear on scissors and shaft sleeves, and tighten loose fasteners.
  11. Second-level maintenance: During annual maintenance based on the "Annual Equipment Maintenance Plan," record the results in the "Equipment Maintenance Record."

Safety Precautions:

  1. Filling operators must wear gas masks, protective goggles, and gloves.
  2. Operators are not allowed to leave or abandon their posts.
  3. Immediately stop the machine if anomalies such as bottle jamming or overturning occur during operation.
  4. Maintain orderly arrangement of materials and promptly handle defective products.
  5. Ensure orderly bottle entry and discharge to avoid spillage and contamination; address any spillage promptly.
  6. In case of chemical leaks, close operation valves promptly, perform absorption treatment, and dispose of hazardous waste properly.
  7. Utilize forms: "Filling Machine Daily Inspection Checklist," "Filling Machine Lubrication Manual," "Lubrication Record," "Critical Equipment Operation Record," "Equipment Maintenance Record."

TAG:  filling machines

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