Factors of the Equipment Itself
Accuracy of the Metering System
Accuracy of Sensors: The accuracy of weight sensors in weighing-based metering and flow sensors in volumetric metering, etc., directly determines the accuracy of the filling volume. High-precision sensors can control the measurement error within a very small range, such as ±0.1%, while the error of low-precision sensors may reach ±1% or even higher.
Performance of the Metering Pump: The machining accuracy, sealing performance, and stability of the metering pump are crucial to the filling accuracy. High-quality metering pumps have stable flow rates and small pulsations, allowing for precise control of the fluid delivery volume; however, metering pumps of poor quality may result in inaccurate filling volumes due to internal leakage, wear, etc.
Mechanical Transmission Components
Accuracy of the Servo Motor: The positioning accuracy and rotational speed control accuracy of the servo motor affect the accuracy and stability of filling. High-resolution servo motors can achieve precise angle and speed control, making the movement of the filling head accurate and ensuring that the filling volume is consistent each time.
Accuracy of the Transmission Mechanism: The accuracy and wear degree of transmission components such as gears, chains, and belts will affect the accuracy of power transmission. If there are gaps, looseness, or wear in the transmission components, it will lead to inaccurate movement of the filling head and affect the filling accuracy.
Design and Manufacture of the Filling Head
Structure of the Filling Head: The shape, size, and internal flow channel design of the filling head affect the outflow speed and uniformity of the alcoholic beverage. A reasonable structure can make the alcoholic beverage flow out smoothly and evenly, avoiding dripping, splashing, etc., which affect the filling accuracy.
Machining Accuracy of the Filling Head: The machining accuracy of the filling head determines its fit with the bottle mouth. A filling head with high machining accuracy can closely fit the bottle mouth, preventing the leakage and backflow of the alcoholic beverage and ensuring the accuracy of the filling volume.
Factors of Material Characteristics
Viscosity of the Material
Alcoholic beverages with high viscosity have poor fluidity and are not easy to flow out smoothly during the filling process, which may lead to slow filling speed and insufficient filling volume. For alcoholic beverages with relatively high viscosity, such as mead, it is necessary to appropriately increase the filling pressure or extend the filling time to ensure the filling accuracy.
Alcoholic beverages with low viscosity have good fluidity but are prone to phenomena such as splashing and dripping, making the actual filling volume unstable. For low-viscosity alcoholic beverages such as vodka, higher requirements are placed on the sealing and control of the filling head.
Temperature of the Material
Temperature changes will affect the volume and viscosity of the alcoholic beverage. Generally speaking, as the temperature rises, the volume of the alcoholic beverage expands and the viscosity decreases; as the temperature drops, the volume contracts and the viscosity increases. For example, when filling beer at different temperatures, it is necessary to adjust the filling volume setting value according to the temperature change.
Factors of the Production Environment
Ambient Temperature and Humidity
Changes in ambient temperature and humidity will affect the physical properties of the alcoholic beverage and the performance of the equipment. A high-humidity environment may cause water vapor to condense on the surface of the equipment, affecting the performance of electronic components and the lubrication of mechanical parts, and thus affecting the filling accuracy.
Cleanliness
Dust, impurities, etc. in the production environment may enter the alcoholic beverage or block the filling head and metering system, resulting in unsmooth filling or inaccurate metering. For example, in a dusty environment, dust may enter the filling head, causing dripping or insufficient filling volume of the alcoholic beverage during the filling process.
Factors of Operation and Maintenance
Equipment Debugging
Whether the settings of filling parameters such as filling speed, filling time, and filling pressure are reasonable directly affects the filling accuracy. During debugging, it is necessary to optimize according to factors such as the characteristics of the alcoholic beverage and the bottle type. Otherwise, there may be situations of overfilling or underfilling.
Daily Maintenance
Regular maintenance work such as cleaning, lubrication, and calibration of the equipment is the key to ensuring the filling accuracy. If the filling head and metering system are not cleaned in a timely manner, it may lead to material residue and blockage, affecting the accuracy; if the metering equipment is not calibrated regularly, the metering error will gradually increase.
