Pharmacy Pill Counter: The Complete Buying Guide in 2025

Isn’t much more tedious and time-consuming to count pills manually? How new advancements and technologies have found innovative solutions to ease counting tasks in pharmacies?

Say BYE to manual tasks or human counting error because the pharmacy pill counter has emerged as a reliable automatic solution for counting pills especially concerning ease of dispensing for pharmacists and pharmacy technicians worldwide. A pharmacy counter is a state-of-the-art machine that offers pretty amazing features and an excellent concept of reducing error-free counting with hassle-free working training or requirement of manpower. You guessed right! Today, we’ll be talking about ‘Pharmacy Pill Counter’. If you’ve decided to purchase a machine then read this blog, we promise it would be worth read experience.

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1.What Is A Pharmacy Pill Counter?

A pharmacy pill counter is an innovative equipment used for counting pills accurately. Side by side, this machine helps in filling of pills into their respective packaging containers. There’s no secret that every pharmacy consumes a huge time in the dispensing of pills, verifying the process, and counting them. Despite an easy solution, most people make this procedure time consuming by practicing old methods.

A pharmacy pill counter is the answer that emerged as the most advanced machine allowing pharmacists to perform the pill counting process easily, accurately, and rapidly. Thanks to technology, where pharmacy pill counter has offered a safer and better way that is capable of counting pill with reduced labor cost, and allow all therapeutic medicine and other products counted in a more standardized and scientifically technical way.

2.Where Do You Use The Pharmacy Pill Counter?

A pharmacy pill counter is a versatile machine that can be adjusted anywhere in the production facility to facilitate end-user. Surprised? Let’s find their uses in industrial and other sectors:

Pharmaceutical Industry

Pharmacy pill counter- picture courtesy- verywell health

This industry is a leader involved in counting and filling of pills, tablet, capsules, etc., therefore, most of the pharmaceutical industry use pharmacy pill counter to count medications of all sizes, shapes, and weights quickly and accurately with ideal packaging options.

Nutraceutical Industry

Pharmacy pill counter- picture courtesy- CAPSULIN

The nutraceutical industry are equipped with pharmacy pill counter to streamline the production cycle of manufacturing and packaging of supplements that are produced in the form of capsules, tablets, and pills., to improve counting and reduce the probability of errors.

Stationery Industry

Pharmacy pill counter- picture courtesy- stationery bazar

A pharmacy pill counter is referred to use in the stationery industry for counting stationery items like pencils toppers, fancy beads, sharpeners, office supplies, paper clippers, etc.,

Food Industry

Pharmacy pill counter- picture courtesy- Woolworth

In this industry, a pharmacy pill counter is used to count and filling of food products like gummies, nuts, chocolates, coffee beans, candies, and related products, this machine can cater products in bulk as well as medium to small quantities ensuring effective food packaging.

Veterinary Industry

Pharmacy pill counter- picture courtesy- EMPR

For any veterinary technician, filling and counting medication manually is always a tiresome job in the clinics. A pharmacy pill counter is the most affordable and versatile counter popular for veterinary clinics and offices worldwide due to its quick and effective counting of pills, tablets, and capsules to save staff time and energy.

Pharmacy

Pharmacy pill counter- picture courtesy- healthcare capsa

Pharmacies and retail supply firms are always hooked to pharmacy pill counter to simplify complex pharmacy in-patient and out-patient applications in a time-saving manner and with reduced dispensing error. One must keep in the mind that in hospital pharmacies, retail pharmacies, and other healthcare units, a minor error can be turned into a serious problem; therefore, pharmacies prefer pharmacy pill counter to ensure patients are receiving error-free medicines every time.

Education

Pharmacy pill counter- picture courtesy- strive pharmacy

Many top education sectors and research centers use pharmacy pill counter due to their simplicity and accurate throughput on health campuses. All prestigious organization trust on pharmacy pill counter due to its effective, cost-friendly, and user-friendly features.

3.How is Pharmacy Pill Counter Useful?

Besides making your workload easier, a pharmacy pill counter is suitable investment that pay offs you in many different ways:

Speed Up Your Pill Counting

Every busy pharmacy and other relevant professional sector spend most of their time in counting pill for dispensing using a hand counter or manual method, such as a tray or spatula is one of the technical ways but it is tedious to perform for a longer term. But advanced pharmacy pill counter can help you in a fast and accurate way as every filled prescription is accurate and with improved output, volume, and efficiency.

NO Dangerous Errors

Picture Courtesy- The Guardian

A practical problem with a manual pill counter is as you increase the counting speed, it will likelihood to cause human error. Fill prescriptions or medicine with accuracy level is paramount in the healthcare sector. With a 99.99% accuracy level, a pharmacy pill counter is proven as the utmost equipment with no dangerous errors. So, now consumers and patients will have properly dispensed medicine with accurate quantity each time.

Employee Satisfaction

Picture Courtesy-Renvue

Nobody prefers joining any organization where they’re asked to spend their days counting pills. It will numb their minds with extra work pressure by focusing on accuracy. A pharmacy pill counter is a good solution where employees can enjoy their days accomplishing extra important tasks rather than wasting their energies in counting pills.

Accurate Counting

Committing a counting mistake can make you repeat the procedure again. The key benefit of a pharmacy pill counting machine is to save your time with accurate counting and improve high efficiency of a production line.

Prevention of Contamination

Pharmacy pill counter

With stainless steel body makeup, a pharmacy pill counter saves your product against cross-contamination or any risk of interacting with foreign particles that mostly stick with parts of the body. The machine has lesser contact with pills and does not cause any contamination to pills during counting.

4.What are Pharmacy Pill Counter Components?

Part	Description
Hopper	This is a storage container which is located at the top of the machine that helps in accumulating a bulk quantity of pills respectively, that release them once receive signals from the PLC system. It allows a fast and seamless flow of pills due to vibration or force of gravity that force down the pills for dispensing.
Alarm Lamp	A visual lamp indicator that alarms the operating user if any unusual condition meets and interrupts the production line e.g. error in equipment, process completion, emptying of hopper, or overheating of the machine, etc,.
Emergency Button	An emergency button that is featured with a high degree of safety ensures end user meet unexpected situations safely. Once you press an emergency button, the system stops working immediately and regulates seamless procedure.
Touchscreen	This is the user’s interface that can add and configure the protocol, and settings, troubleshoot, visualize the progress, and find important alerts through the procedure. A pharmacy pill counter featured safety alerts also received on the PLC touchscreen. Now, you can control the entire work process just by clicking the keys available on the screen.
Observe Window	Along with visual monitoring using cameras, an observing window is also equipped in the machine just behind the hopper and other parts of the machine such as feeding heads which are featured with transparent material allowing the user to see the area and movement or transportation of pill during the process. It is a gateway visualization of the insight process.
Filling Head	The number of pills enters the filling head where a camera/sensor visualizes the pills and sends them to the filling nozzle for precise dropping into containers.
Adjustable Filling Nozzle	Every container or bottle has a different shape or size. That’s why an adjustable filling nozzle is equipped in the machine that allows you to modulate the setting according to container and find direct counting and filling of the pill inside each container perfectly.
Adjustable Lift Holder	This part of the machine supports the filling head, hopper, or the upper part of the machine to the lower part that is involved the conveyor, electrical components, rejected unit, etc., The adjust features help in correcting the conveyor or height of the machine.
Adjustable Lift Screw Holder	The movement and alignment of the machine are entirely supported by adjustable lift screw holders that are responsible for fine-tuning of the lifting parts.
Lift Conveyor	The incoming and outgoing packaging containers for pill counting and the filling procedure are supported by a lift conveyor.
Sensor	Advanced or automatic pharmacy pill counters are featured with sensors that detect the presence of pills and mark them as counted and mention the message on the system. This unit helps in accurate and error-free dispensing of the pill.
Lift Base	The pharmacy pill counter machine is lifted in an upright position due to base of the equipment that offer smooth and reliable lifting by strong and fixed pads that are resistant to shock, vibration, and displacement.

5.How to Classify a Pharmacy Pill Counter?

There are various types of pharmacy pill counters that offer excellent mechanisms, designs, and features. We have simplified the following types of pharmacy pill counter for your understanding.

BASED ON AUTOMATION

In this category, we have further sub-classified the pharmacy pill counters:

Manual Pharmacy Pill Counter

Manual Pharmacy Pill Counter-Medium.com

This is the oldest and the most conventional method of counting pills using a tray and spatula. On the tray, you can pour a number of pills subjected to be counted and manually count them one by one by moving spatula and directing on the pill. This is the most simplest form of pill counter as well as pocket friendly too. But this way of counting pills is associated with some limitations as it is a tiresome method that required high focus, energy, and manpower. The most important drawback is it is not accurate and time-consuming. This is the preferable machine for short or small businesses that do not require any training.

Semi-Automatic Pharmacy Pill Counter

Semi-Automatic Pharmacy Pill Counter

This is a great way of catering to medium to large batches of pharmacy pill counting that will require less manpower and time. Here, you need to load the containers where machine counts and fill them. Once the pills are filled, you need to pick the containers and place the next one. This type of machine is featured with PLC featured that can work by interpreting infeed data by you. But, it would require continuous involvement of the user to load and remove the containers and place new packaging material. Overall, this machine gives you a fast and reliable outcome.

Automatic Pharmacy Pill Counter

Automatic Pharmacy Pill Counter

This is the most preferable equipment adopted by popular and competitive industries that strive to make their profitability and wants to run large batches day and night without requiring fixed operator involvement. This is an automatic solution where the user just has to click the keys using PLC and the remaining setup would be run be the machine. This machine offers the fastest and the most reliable counting outcomes than other available pill counting solutions.

BASED ON MACHINE DESIGN

Based on design, a pharmacy pill counter are categorized onto two basic types:

Rotary Pharmacy Pill Counter

Rotary Pharmacy Pill Counter

This is a machine where movement of pills are taken placed by a rotary bowl that are features with multiple channels inside that helps in alignment of the pills and counts them automatically. This machine has compact designing offering hassle-free counting options with more accuracy.

Multi-Channel Pharmacy Pill Counter

Multi-Channel Pharmacy Pill Counter

This is the most common design featured with multiple channels for transporting pills via continuous vibration in a gentle manner. This machine can cater to the pill counting process for large quantities and preferable option for large industries where a non-stop counting process is required.

BASED ON COUNTING HEAD

Based on counting heads, a pharmacy pill counter is divided into two types:

Single Head Pharmacy Pill Counter

Single Head Pharmacy Pill Counter

This machine has a single counting head that is preferred for moderate production sectors. This machine is featured with an automatic system accompanied end user with excellent working options such as a detector system, PLC control etc.

Multi Head Pharmacy Pill Counter

Multi Head Pharmacy Pill Counter

This machine is the most suitable solution for running a production line with the greatest speed and accurate results. Here, the machine is equipped with multi head channels that ensure thousands of pills counting per hour.

6.How is Pharmacy Pill Counter Work?

A pharmacy pill counter works by the involvement of multiple steps such as:

STAGE 1 Infeed

Infeed

At this stage, pills are prepared to be counted and dispensed where they are fed into the system manually directly into the hopper of the machine.

The pills or tablets come on vibratory trays where the presence of a camera assesses the pill using various ways such as weight sensors and visualization using optical sensors to find the correct shape or appearance of the pills to be counted.

STAGE 2 Counting

The presence of pills are determined by detectors and add them as a count by the help of software that employed an algorithm to distinguish various types and size of pill as well as notify if any unwanted particle is present in the following tray.

STAGE 3 Dispensing

Each counted pill steadily transfers into the container for the final packaging of the product and send it to the next machine such as capping.

7.What Integrated Units of Pharmacy Pill Counter?

Running a pharmacy pill counting production line is not an easy task! But it is not impossible to drive it smoothly by creating a set of efficient and right machines. Read below for the recommended set of machine that can combinely make a better production line:

	Machine	Working
Bottle Unscrambler	Whether your packaging material is bottle, containers, jars, or small cans. A bottle unscrambler is worth-adding equipment that is used to position and correct the containers for the next machine ensuring a controlled flow of pills into the right container in a subsequent process.	Bottles from hopper enters into the feeding tray that upon vibrations or using compressed air orients the position and supply it onto a seamless channel that direct them toward next machine.
Pharmacy Pill Counter	This is main leader machine of the pharmacy pill counting production line that upon entrance of containers feed the accurate or assigned or pre-determined numbers of pills for packaging.	This machine works by a sensors system that detects and counts the presence of each pill knock down from the filling nozzles. Machine works by following a simultaneous mechanism of photo-electric sensors, vibratory channels and computerised system of recording and displaying data.
Desiccant Inserting Machine	An addition of moisture absorbing desiccant is sometime considered as optional step for various production industries. But when it comes to healthcare, food, and other field, this machine used and integrated after pharmacy pill counting machine to insert desiccant into each container to keep pills in favourable condition and protect them against progressing humidity inside.	A desiccant film which is supported by a dancer arm allow uncoiling of the strip automatically. The presence of cutting knives separate each strip and places each packet into individual container and sends it to the next machine.
Pill Capping Machine	To maintain the freshness, fragrance potency, and efficacy of the pharmacy pill dosage form, a capping machine is integrated soon after desiccant inserting machine that helps in securing containers by screwing caps around the bottle neck.	Machine works by using sucking caps from the hopper; by the help of torqu application, capping are mounted and twisted on the each container and tighten up to keep product safe.
Induction Sealing Machine	A tamper proof packaging is of paramount important when it comes to pack pharmacy pill. An induction sealing machine is a cost-effective solution that enclose the container and creates a secure seal around the product’s caps proving them safe and authtentic.	Machine works by inducing electromagnetic field that helps to warm the sealing layer embedded insight the caps of the products. Upon lowering down the temperature the melted sealing layers firms and cool down and binds to create a hermetic seal on the closure.
Labeling Machine	This machine plays important role in improve your brand and creating aesthetic appearance of the product. Label on each product convey brand’s name, information, dosage instruction, manufacturing, expiry date, and other relevant information.	The machine works by unwinding the roll, machine detects the presence of the container where label is pasted using via pressure sensitive method or glue adhesion method followed by pressing of label using pressing rolls present in the machine.

8.What Other Products Can Pharmacy Pill Counter Counts?

A pharmacy pill counter is versatile addition to run various products other than pharmacy; that’s the reason this machine offers a significant role in many other production sectors also. Lets’ find what other product can be counted using this robust machine.

Hard Gelatin Capsule	A hard gelatin capsule composed of a body and head filled with pellets, powders, and granules. This medication is commonly used after tablets can be counted accurately using the pharmacy pill counter.
Soft Gelatin Capsule	Hermetically sealed soft gelatin capsules are commonly used in the nutraceutical, pharmaceutical, and cosmetic industries and can be dispensed using this machine.
Tablets	The most commonly used solid dosage form can be counted and filled using a pharmacy pill counter. This machine is helpful in counting tablets of various shapes, sizes, and weights.
Gummy Candies	Elastic, sticky, and chewy gummy candies are another product that can be dispensed using a pharmacy pill counter. These candies are prone to stick but the present machine is made up of stainless steel that has minimum contact with candies and dispensed them fastly so it offers high protection and the product’s stable quality.
Lozenges	A small tablet that becomes dissolves in the mouth once you administer it. A pharmacy pill counter is useful in dispensing and counting these dosage form
Candies	Along with medication, tasty and sweet candies are filled in packaging sachet, pouches, and jars using pharmacy pill counters.
Coffee Beans	A pharmacy pill counter is also used to count and fill coffee beans and dispensed them in the assigned jars safely.

9.What Type of Packaging Material Can be Supported with Pharmacy Pill Counter?

A pharmacy pill counter can not only allow various products to cater but it is capable enough to count and directly fills various packaging material types as well. For example:

Jars

Jars

Whether plastic or glass jars, a pharmacy pill counter can deal with filling purpose with the bits of help of a conveyor that ensure easy infeed and outfeed movement of these materials.

Sachet

Sachet

A pharmacy pill counter can count and fill the desirable product into respective sachet and send them for the further sealing procedure.

Stand-up pouches

This is one of the commonly used packaging material used for dispensing pills and other products like beans, candies can be compatible with pharmacy pill counter to achieve desirable outcomes.

Bottles

Bottles

A pharmacy pill counter is compatible machine can allow bottles for packaging and storing the counted pills accurately.

10.What are the Problems and Troubleshooting of Pharmacy Pill Counter?

A pharmacy pill counter is an electronic device that can also encounters with some unwanted problems like other equipment. We have discussed some common problems and their easiest solutions below:

Pills are Filled but not Displayed

Picture Courtesy- Pharmafill USA

This is a common problem where the machine accurately fills the assigned number of pills but the system does not show it. It can be caused when a machine is operating for a longer time and other internal software needs to be updated.

To solve this problem re-calibrated the machine. Plus, re-install or re-update the software. Run the test procedure and re-check.

Jammed Pharmacy Pill Counter

Picture Courtesy- Deitz

This is another common trouble that interrupts the process where the machine system becomes stuck. This is commonly caused if a foreign particle or any broken parts of the pills got stuck in the moveable channels or units.

To fix the problem, we would recommend cleaning the movable parts such as the conveyor, filling nozzle, head of the counter by using dry cloth and compressed air. Make sure the pill transporting passage is cleared and restart the machine and intiate the process.

Inaccurate Counting of the Pills

Picture Courtesy- Cremer

This is the common problem with semi-automatic and automatic pharmacy pill counters where machines dispense an inaccurate counting of the medications. This problem can be caused due to improper loading or misalignment of the vibratory channels, hopper settings, or exposing parts that are dirty.

To solve the problem, reset and re-align the parts such as the hopper, and vibratory tray, and check the sensor of the machine. Plus, clean the machine and reassure that any debris is there or not. Start the machine and repeat the procedure to assess if everything is working properly.

11.What Points to be Considered for Purchasing Pharmacy Pill Counter?

When purchasing a pharmacy pill counter, one must go through the following consideration factors to avoid problems in purchasing the wrong one.

Economical

You must keep your pocket budget in your mind to buy the correct machine up to your requirements. If you have a limited budget, we recommend opting for digital or semi-automatic machines that can also be offering amazing features in a pocket-friendly manner.

Integrating with Other Units

Do you need a standalone machine or running a large production line? A buyer must know this factor to purchase a complete set of machines. For e.g, for integrating equipment you need conveyor belt options and connecting parts that would allow you to integrate the machine with other units in no time.

Production Capacity

What is need of user is the important point you must consider and pick the exact solution for it. Whether you’re running a small production process, or require dispensing of medication day and night. Then consider pharmacy pill counter that deals with moderate or high production capacity per each running session.

Size and Portability of the Machine

You must know the size of the required machine. Whether you have a small installation space or a large one is a prime factor you should discuss with the manufacturing company so they would design the planner and suggest the pharmacy pill counter that would easily install in your facility that must be featured with portability options.

Conclusion

A pharmacy pill counter is a versatile machine used for every production sector that deals with counting and dispensing solid dosage medications such as capsules, tablets, caplets, or food products like gummies, candies, etc., This is a promising addition that helps significantly in skyrocketing the business. For that choosing the right machine is always important that will take your business up to a greater level of achievement and success. So, why not invest in purchasing a ‘pharmacy pill counter’ machine? Please contact us to find amazing series of pharmacy pill counter with free consultations right now!

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Capsule Counting and Filling Machine: The Complete Buying Guide in 2025

Capsule Filling Machine

Capsule Counting and Filling Machine: The Complete Buying Guide in 2025

Do you want a capsule counting error was just a problem of past? Are you looking for revolutionize your production business with new levels of success?

Today, where everyone looks for perfection a capsule counting and filling machine importance cannot never be neglected. This is a significant equipment give an outstanding result in the term of saving your time, offer accuracy and catering bulk production.

Before investing on capsule counting and filling machine. We would suggest you read through this blog to find updated guidance about what you look for.

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1.What is Capsule Counting and Filling Machine?

A capsule counting and filling machine is a specialized equipment that assist in counting and filling of capsule in huge quantities without any involvement of manual handling. This machine offers the user trouble-free operation in various industries for various applications.

The counting and filling product include hard gelatin capsule, soft gelatin capsule, and various types of products we discussed below. Moreover, the machine performs this function precisely with use for advance features like filling nozzles, sensor, touchscreen system etc. that helps in running process with reduced chances of product’s spillage or errors.

2.What are industrial uses for Capsule Counting and Filling Machine?

Capsule counting and filling machine has a wide range of applications and can be used in several manufacturing industries such as pharmaceutical, chemical, food, agriculture, and cosmetic industry. Let’s discuss each of these industries below.

Pharmaceutical Industry

This industry deals with the production of medicines and drugs which are needed to cure illness and disease. capsule counting and filling machine will be very important to this industry since it needs an accurate counting and filling equipment to ensure proper dosage for safe consumption for e.g pills, tablets, and gummies.

Chemical Industry

Many chemicals such as aluminum beads, buffer pellets, and others need an effective way counting and fill them safely. This can be done with the help of capsule counting and filling machine which can offer a secure way to package them into pouches or bags to keep them safe from harmful external factors.

Food Industry

Picture Courtesy-Sam’s club

Food items such as food tablets, and candy can be filled into decorative boxes by using capsule counting and filling machine. This will ensure that they are packaged safely to preserve their freshness and prevent them from getting stale.

Nutraceutical Industry

This industry is involved in the manufacturing of food tablets and vitamin supplements which are used to improve people’s lifestyles. Using capsule counting and filling machines would be a great option to fill this nutrition filled products into jars or bottles.

Agriculture Industry

Many agriculture products which are derived from crops such as wheat, maize as well as pellets and fertilizers need capsule counting and filling machine to package them safely so that they can be protected from harmful environmental factors and ensure their proper transportation to their destination.

Cosmetic Industry

Picture Courtesy-GoSupp

Cosmetic industry utilizes capsule counting and filling machine for packaging material like capsule facial serum, waxing beads, manicure, pedicure material such as bees wax beads, paraffin beads etc.,

Stationery Industry

Picture Courtesy-Amazon

This production sector uses a capsule counting and filling machine for packaging materials such as erasers sharpeners, fancy tools like keychain toppers and other into assign packaging containers.

3.What Is the Working of Capsule Counting And Filling Machine?

A capsule counting and filling machine is a robust counting solution that follows pretty simple working principle. The various different models which may offer slight difference in working but the major steps are the same. Our cleared demonstration about each step is given below:

Infeed

Infeed

This is the first step where packaging containers are loaded onto the system that mostly fed via machine of an integrated system such as unscrambler machine. The operator feed in the parameters using PLC and Starts the machine where hopper that is loaded with capsules bulk starts to transfer them toward the next phase.

Detection Phase

Soon after feeding, capsule are moves toward filling procedure via detection phase that helps in assessing the physical appearance of the capsule. For e.g., color, texture, stickiness or smoothness, etc., The objective of this phase to allows stable and correct capsule and rejects the faulted one.

Counting and Filling Phase

There are various vibratory channels that transport the aligned sequence of the capsules toward filling nozzles where sensors help in showing presence of each capsule and notify it as counted one and drops them into filling containers. This is the fastest process where hundreds of capsules pass through the filling nozzles in each minute.

Discharging

Upon filling the container, it moves and allow next container. The filled container discharge the machine by the help of conveyor and integrate with the other unit of the production line.

4.What Are the Major Parts of Capsule Counting and Filling Machine?

A capsule counting and filling machine is a multi-dimensional equipment which is designed with assembling various important parts to give you accurate capsule counting and filling task. The list of following components of capsule counting and filling machine are discussed below:

Hopper

This is the major core of the machine that performs a substantial role in storing optimum quantities of capsules that waits for counting and filling procedure. This is also positioned as the most above of the machine to carry seamless flow of the material into each packaging container via gentle vibration to begin the counting process.

PLC Control

A programmable logic controller is known as the brain of the machine that integrate various factors into it and receive input from user and send messages to each component to achieve working.

Filling Nozzle

This is a vibratory unit that are equipped with detection channels offering continuous vibration to facilitate the dropping of capsule in proper way toward packaging container. Some machine are designed with more than one filling nozzle to run fast counting and filling of capsule in every minute.

Counting Head

The capsule counting heads allow accurate number of capsule toward filling nozzle. The series of processes take place following proper detecting channels.

Conveyor

This unit acts as a transporter that ensure smooth infeed of packaging container toward filling nozzles. Upon counting and filling process, the conveyor belt moves and discharge the container followed by allowing next.

Rejection Unit

If any capsule is deformed or damaged, there are directly rejected and discarded to rejection unit. This unit safeguarding the production system ensuring end-user that counted and filled containers are accurate and consistent.

Sensors

A high-degree sensors acts as gatekeeper of the machine that detects the presence of the capsule and mark as counted toward the PLC unit. Plus, if your product is damage, sensors notifies and send them toward rejection unit to proceed production as uninterrupted.

Stainless Steel Body

A capsule counting and filling body is made up of highly durable stainless-steel body that offers safety, reducing cross-contamination, and ease of cleanliness.

Electric Box

All electrical components such as wiring, switches, plugs of the machine are enclosed in a cabinet that helps in regulating electrical activity under safe manner.

5.How Capsule Counting and Filling Machine Benefits You?

A capsule counting and filling machine is absolutely essential requirement of today’s industrial production unit. This is because of several beneficial factors it offers you every time. Such as

Super-Fast

Switching On The machine with feeding the data such as running speed, counting and filling process will begins with process to give you exact number of capsule counting and filling need every time. This is super-fast solution than manual handling.

Super Accurate Counting and Filling

Making errors was a thing of the past. A capsule counting and filling machine is super accurate in the term of counting due to high advanced technology that senses once capsule strike on the counting channel.The presence of detectors and featured cameras ensuring exact number of capsules that fills in the container every time.

User Friendly- Easy to Use

Indeed, a capsule counting and filling machine is a compact and robust counting and filling machine that allows users with easy operating access by using touch screen parameters to control the system.

Easy to Mingle with Other Machines

This is well-structured and designed with professional skills which allows to integrate with other machines to run the production unit smoothly. For e.g. unscrambler, washing machine, labelling machine. Etc.,

A Time Saver

Picture Courtesy- Busch Machinery

Nevertheless, spending hours and energy on manual counting and filling procedure is now replaced with a time saver solution of incorporating a capsule counting and filling machine into your production business.

Boosting Production

Picture Courtesy-Sanle

A capsule counting and filling machine is a promising machine that helps in growing your business in saving multiple options like money, time, energy, manpower and other.

6.What are the Types of Capsule Counting and Filling Machine?

There are several types of capsule counting and filling machine that gives efficient functionality to the end-user depending on their requirements. Such as:

BASED ON AUTOMATION

Based on automation, a capsule counting and filling machine is categorized into the following:

Manual Capsule Counting and Filling Machine

This is most preferable type of capsule counting and filling machine for smaller businesses. This is because it is cost-economical and easy counting solutions where capsules are spread onto the counting try where it can fix into each cavity and helps you in error-free counting. The entire procedure can be performed by user himself. This is an easy to use machine which do not require any tips, trick, or training.

Semi-Automatic Capsule Counting and Filling Machine

This is the smart solution for medium to large production batches where loading and unloading of containers can be done manually, but remaining functions can be performed automatically. This machine can run medium to large batches in hours. Therefore, many industries and hospitals use semi-automatic machines as it gives you accurate and fast result.

Automatic Capsule Counting and Filling Machine

This is an advanced solution for top-notch production industries and excellent machine for running hassle-free large batches without requirement of any manual operation. You just need to feed in the parameters and switch on the machine. This machine is equipped with sensors, detectors and multiple channels, etc., that allows end-user with accurate output. This is the reason this is the most demanded and popular equipment that offer high profitability and business success.

BASED ON MACHINE DESIGN

Based on design, a capsule counting and filling machine is categorized into the following:

Rotary Bowl Capsule Counting and Filling Machine

This is a vibratory capsule counting and filling machine which is equipped with rotary bowl feeding unit that supply and counts capsules automatically and accurately. A rotary bowl is fixed with vertical base that moves and allows capsules to arrange and sort them selves by dropping into channel or pockets. This machine is also a fastest unit ensuring precise and error -free results.

Multi-Channel Capsule Counting and Filling Machine

This machine is featured with multiple channel that helps in counting and filling of capsule by offering them gentle shaky pathway to capsule at the same time. This machine is worth buying for large production sector as it can cater bulk production processes automatically.

BASED ON COUNTING HEAD

Considering counting heads, the capsule counting and filling machine is divided into the following:

Single Head Counting and Filling Machine

A capsule counting and filling machine featured with a single counting head offering precise and accurate throughput. This machine is suitable for moderate production capacity lines.

Multi Head Counting and Filling Machine

A multiple counting heads of capsule counting and filling machine is an exceptional advancement that has emerged and adopted by largest production companies for fastest and error -free counting and filling tasks.

7.What is the Production line of Capsule Counting and Filling Machine?

Capsule counting and filling machine has completely streamlined of different machines comprised to form a production lien for mass production in several industries according to the product specificity.

Machine	Description
Bottle Unscrambler	These machines ensures proper alignment of empty bottles throughout the production line to enable smooth and continuous processing without causing any interruptions.It is the primary to prevents the jaming of the bottles in bulks in the conveyor system. It helps in the maintenance of product quality by minimizing the risk of overfilling and underfilling.
Capsule Counting And Filling Machine	Capsule counting and filling machines are used to count and dispense capsules with high precision and accuracy.This machine helps increase product efficiency by saving time and human exposure, preventing contamination.
Desiccant Inserting Machine	For moisture sensitive capsules, these machines are used to insert desiccant pouches in each bottle accuratly to assure and physical or chemical changes induced by humidity. It profoundly contributes in consumer satisfaction and safety.
Capping Machine	Capping machines are used to seal the container by different snap caps, Roll on caps, crown caps, plastic caps as part of production line. It works with high production speed by reducing the production costs and most commonly used in food and beverages industries and phrmaceuticals.
Induction Cap Sealing Machine	For providing leak and spilling proof airtight seal as a preventive measure for moisture sensitive tablets by induction cap sealing machines. These machines assures quality of the product from any physical and chemical changes induced by humidity.Being the last step in the production line, it adds on an extension in the quality of the product.

8.What Type of Products Can Capsule Counting And Filling Machine Fill?

Capsule counting and filling machine is one of a kind which can package any product. So, it can build your company to a profitability for catering various products such as:

Hard gelatin capsules /Soft Gelatin/Tablets/Pill The solid dosage form such as pills, tablets, various capsules require capsule counting and filling machine to package them into pouches or bottles and known as a great way to cater to mentioned products.
Candies/ Gummy Candies Candies/ gummy candies are confectionary sweetened items which need accurate packaging to maintain weight and fill required number of items. These candies are packaged with the help of capsule counting and filling machine, thus, preventing any counting error and cross-contamination during handling.
Wax Beads These are solid, circular shaped substances which when heated get liquefied and are then used to remove body hair. Packaging them into pouches using capsule counting and filling machine would be a sustainable move.
Laundry Pods Laundry pods are small sized capsule like balls which are filled with liquid detergent in a predetermined quantity. They can be easily packaged by using capsule counting and filling machine.

9.What Type of Packaging Material Capsule Counting And Filling Machine Can Fill?

Are you wondering whether this machine will be able to fill capsules in not just one, but several different kinds of packaging, giving you an edge over other companies in terms of attractive and versatile packaging? Then yes! It has the ability to fill your products in different kinds of packaging materials of various shapes and sizes. These are:

Sachet

This easy to tear, flexible and convenient packaging can be used to store any kind of supplements or powdered medicine inside. Capsule counting and filling machine can fill the desired product into these sachets by the weighing filling method in a predetermined quantity.

Stand-Up Pouches

This packaging is one of the most flexible ones out there. It prevents the spillage of the product and keeps it fresh and secure. A capsule counting and filling machine helps you in the counting and filling of these capsules into these pouches efficiently.

Bottles

These bottles are made with highest quality materials to increase the shelf life of the capsules. They protect them from sunlight, air and moisture by preventing their contact with the capsules inside. Capsule counting and filling machine is the suitable machine to perform counting and filling of these bottles perfectly.

10.How To Clean and Maintain Capsule Counting and Filling Machine?

Just like every other machine which requires proper maintenance and regular cleaning for its optimization, capsule counting and filling machine also requires some steps to increase its lifespan. Below are the ways in which we can do this.

11.What Are Common Problems and Troubleshooting of Capsule Counting And Filling Machine?

Problem	Solution	Picture
Capsules are Filled but not Displayed This problem is accompanied by abnormal counting and overfilling of container without notifying the counting of each capsule.	Locate the sensor and reset it. Clean the sensor using alcohol dampened cloth on glass eye in a vertical and horizontal motion. Visually inspect and assure no debris or obstacle is presented there.
Capsules are Miscounted This is the problem where capsules are miscounted due to overlapping of content or too excess height of the hopper or poor counting sensitivity.	Slow down the counting speed. Re-adjust the height of the hopper to the filling nozzle. Wipe the sensor surface using above cleaning method.
The Unit Counts Itself This is the problem that is occurred due to poor sensitivity to detector. Plus, System setting were not calibrated.	Clean the sensor. Recalibrate the setting. Re-feed the data. Run a test to evaluate the process and proceed the production.

12.What Factors Should Be Considered Before Buying Capsule Counting and Filling Machine?

Are you afraid of investing in the wrong capsule counting and filling machine? Don’t worry! You are not the only one. It is a nightmare for a lot of people who are too worried about the consequences they might face if they buy the machine which is incompatible with their production line. Let’s discuss some of the points which would ensure that you buy the best type for your factory and not incur any heavy losses.

Production Capacity

This factor is important since your factory’s production capacity will decide which type of capsule counting and filling machine you would need to buy. If you have a very high production capacity, then you would need an automatic capsule counting and filling machine to cater to your large-scale business.

Budget Friendly

Capsule counting and filling machine ranges from cheaper manual types to expensive automatic ones. If you do not have any financial restrictions, then go for automatic capsule counting and filling machine, but if you budget is low, then semi-automatic or manual ones would better for you.

Multi-Faceted

Capsule counting and filling machines have many types which have the ability to fill different type of containers. It can fill containers ranging from stand-up pouches, plastic bottles, bags, PVC PET containers and jars. These containers can be easily filled by automatic and semi-automatic capsule counting and filling machines.

Installation Area

It is highly critical for you to check how much area your production line can offer to install capsule filling and counting machine since some automatic machines would take large space. Whereas the semi-automatic or manual capsule counting and filling machine would have low space requirements.

Manufacturer Reliability

Don’t rush into buying capsule counting and filling machine from anyone who’s eager to sell their products. Check his company’s reviews on google and make sure he is reliable by checking if company has authorized documents to prove authenticity and product quality.

Conclusion

In conclusion, a capsule counting and filling machine is a multi-dimensional equipment that performs counting and filling of not only capsules, but many other products such as pill, tablets, candies, beans, etc., Moreover, this machine can perfectly and accurately do this job in a hassle-free manner. So, what are you looking for? If you’re willing to invest in this robust equipment; we would recommend contacting us. Allpack is the hub of providing excellent machineries related to capsule counting and filling purposes. Message us now.

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Induction Cap Sealing Machine: The Complete Buying Guide in 2025

Continuous Sealing Machine

Induction Cap Sealing Machine: The Complete Buying Guide in 2025

How do you ensure that your product packaging is tamper resistant and secure? An induction cap sealing machine is an absolute answer that offers a tremendous technology that has revolutionized the packaging industry in the competitive market across the globe. This machine is a super solution that rapidly provides you with the results that everyone look for in their dream production. Before purchasing we would suggest to please go through this article to know the best knowledge related to this machine. Let’s read!

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1.What Do You Know About Induction Cap Sealing Machine?

Picture Courtesy-Enercon Industries

An induction cap sealing machine is responsible for bonding a foil lamination around the bottle’s neck once they’re filled with packaging material. The induction cap sealing machine works by using electromagnetic power for generating heat waves that weld the liner to the container in order to seal hermetically.

Plus, FDA has quoted this method as an effective way to achieve tamper evident products by providing firm and leak proof seal lining. Also, an induction cap sealing machine is suitable for a long term shelf life of your product by preserving them against unwanted environmental conditions that can interact with product and induce degradation.

The super technology is based on sealing various materials such as plastic, glass caps without contacting them or product. That s ‘why, an induction cap sealing machine is commonly used in healthcare, and food industries as it not only ensuring tamper proof but also integrity of product.

2.Where Is Induction Cap Sealing Machine Used?

An induction cap sealing is widely used in industrial sector due to the tremendous safety applications. Important industrial uses of this machine are described as:

Nutraceutical Industry

Worldwide top-notch nutraceutical industries packaging sectors rely on using an induction cap sealing machine to preserve quality of sensitive compounds such as vitamins, proteins, energy drinks, herbal supplement, enzymes, minerals, trace elements against interaction with oxygen and moisture that induce contamination of rancidity of product.

Food Industry

Manufacturers of food industrial sectors only trust on an induction cap sealing machine as it helps in creation of air-tight packaging of food products and keep them secure till end user. For example, ketchup, mayonnaise, yogurt, milk, sauces, condiments, spices, sweeteners, salts, etc., In fact this is a powerful protection way that satisfies customers with good quality as it guarantees against pilferage.

Pharmaceutical Industry

In pharmaceutical industry where quality, safety, and potency are considered as prime subject of product’s packaging; an induction cap sealing machine has been used for decades for this purpose. The inner foil sealing around the packaging material acts as a barrier against outer environment and locks the freshness and harming against moisture. This is used in production line of packing tablets, syrups, capsules, pills, ointments, medicinal jars, creams.

Chemical Industry

In chemical industry, an induction cap sealing machine is known for its best anti-counterfeit action for important chemicals products like alkali, salts, acids, bleaches, buffers, solvents like distil water, inorganic or organic, lab reagents, or neutral salts solution. Moreover, this machine ensure that sealed products are remain in active form, protected against spillage, and uncontaminated.

Cosmetic Industry

Cosmetic products are mostly sensitive to external environment and must be stored carefully for long term correct applications. For example lotions, serums, face foundations, eye creams, hand creams, pedicure, manicure sets, and other, which are always firmly sealed using an induction cap sealing machine to maintain products quality and offering tamper evident packaging.

Household Cleaning Products Industry

An induction cap sealing machine offering reliable packaging of products like detergents, floor cleaners, dishwashers, shiners and improving confidence in the product’s originality with air-tight and strong sealing.

Agro-Chemical Industry

The manufacturers of agro-chemical industry always seek for an induction cap sealing machine for packaging products like pesticides, herbicides, crops boosters, fertilizers, and other important products to ensure improved and safe handling during farming of crops.

Automobiles Industry

The packaging of automotive products cannot be done if an induction cap sealing machine is missing from its production line. Products like lubricants, engine oils, brake oil, and other fluid can be safely dispensed and stored with the sophisticated lining of aluminium sealings around the neck of bottles.

3.How Does Induction Cap Sealing Machine Work?

The working of induction cap sealing machine is quite simple. The working of the machine relies on heating coil which is induces by an electromagnetic field and its interaction with sealing material presented on the cap. Please look into basic four steps where the science of induction cap sealing takes place respectively.

STEP 1 Preparation

Indeed, this is a major step where bottles are first filled and secured with screwed cap or closure. This cap or closure is designed with an inserted liner which is composed of aluminum foil and thin film of laminated plastic or paper.

STEP 2 Sealing Head Preparation

A sealing head which is designed with an induction coil that helps in transferring of electromagnetic heat radiation and induce the field around the coil area. The surface or position of the head just above the container helps the stimulation of inner layer with heat energy. Before arriving, containers sealing head must be warm with recommended temperature.

STEP 3 Induction Cap Sealing Process

Picture Courtesy-Youtube

The process begins when step 1 and step 2 are ready and set of containers comes in the contact with electromagnetic waves that helps in emerging high-frequency waves which heats the liner. This liner melts and forms a loose bond around the neck of the container.

STEP 4 Discharging

After induction cap sealing process, set of containers leaves the sealing head zone and enters to the normal temperature where sealing cool and becomes to shrink and harden and forms a hermetic sealing layer around the lip of the containers on other words a tamper evident sealing layer is formed.

4.How Induction Cap Sealing Machine Benefits You?

An induction cap sealing machine offer various benefits to manufacturing and packaging companies. Those benefits are discussed below:

Preserve Freshness, Fragrance/Aroma, and Quality of Product

Nevertheless, an induction cap sealing machine is an excellent machine for offering an airtight hermetic sealing that will enclose the packaging against its external interaction of oxygen moisture, and light. This tightly enclosed container will be capable to fragrance or aroma of food products, maintain potency and efficacy of potential drug, or maintain integrity of the product for a longer time.

Tamper Evident Product

There’s no doubt every customer when pay money; they deserve the best one. An induction cap sealing machine offering promising packaging that convey message to potential clients that the purchase product is as original as dispensed by manufacturer.

User-Safe with Improved Product’s Safety

Picture Courtesy-Alibaba

Operating an induction cap sealing machine is super-easy. An operator has to in-feed the data such as heat exposure time, speed of conveyor, etc., and rest of function can be performed safely. You don’t need to worry about overheating the system as system is featured with cooling fan to overcome heat generation inside the system. Plus, a strong sealing of container safe your product against cross-contamination or leakage. So you can get Two in One task by a single machine.

Improving Brand Reputation

Picture Courtesy-Alibaba

By offering tamper evident product across the market regions will gain the attention of professionals due to its appearance and original material can ultimately lead to make a great reputation of your company.

Saving Your Budget

Now you don’t need glue or tape for packaging the lid over the container. An induction cap sealing machine is a reliable and robust solution that can save your money in the most sophisticated way just by-passing hundreds of containers under the zone of electromagnetic waves and that’s it- Your containers are perfectly sealed.

Quality Compliance

Picture Courtesy- Alibaba

This factor is always paramount to all manufacturers who belong to food, beverages, pharmaceuticals, nutraceuticals as they need to be very astringent to health regulatory needs. For this., an induction cap sealing machine is perfect solution as it will bind the liner to container’s neck without affecting integrity of the product and maintain product safety and quality throughout its shelf life.

5.What Are Structural Parts of Induction Cap Sealing Machine?

An induction cap sealing machine is a simple machine that can easily perform complex functions in no time. Let’s go through some important parts of the machine also with their specified responsibilities.

Electromagnetic Induction Head	This unit works as the heart of the machine which generates the electromagnetic high frequency zone around the moving bottle caps that strikes with high-frequency radiation when entering. A mentioned about cap is fitted with liners that become heated when pass by the field and absorb inside. This ultimately melts the firm bond and leads to stick around the rim of bottles and seals strongly upon cooling.
Conveyor Belt	This unit works as a transporting medium that efficiently transports the containers for the induction cap sealing procedure. A set of bottles comes into the electromagnetic field via a conveyor and leaves after exposure. The speed of the conveyor and exposure time can be adjusted by using a PLC system.
Hand Crank Wheel	Some bottles are small while some are not, an induction cap sealing can ensure various height bottles treatment by adjusting the hand crank wheel to set the bottle height with a sealing head or conveyor.
Lifting Bracket	An induction cap sealing machine is supported by lifting bracket which lift the sealing head in an upright position and with vertical alignment. Moreover, it also helps you in maintaining the portion between the machine and the caps of the bottles in order to achieve effective sealing.
Sealing Head	This section ensures the applications of electromagnetic radiation in order to produce perfect sealing. This is located just above the cap liners hence easily gets exposure of bottle caps and provides fast heating.
Guide Plate	As its name shows, it helps containers to stay in an upright position along with the conveyor pathway and ensure bottles are properly positioned following accurate movement for excellent and even sealing.
Cooling Fan	This is well-known to you if a machine produces heat must be prone to over-heat. To balance this a cooling fan is featured within a machine that lowers the chances of overheating and offering 100% safety and security to the operator and the working environment during continuous operation.
Central Control Box	This is known as the brain of the machine that controls the major functions of the operation such as sealing time, exposure time, speed of container movement, etc. Moreover, the operator can visualize the process and get notifications and alerts from this unit.
Power Panel	This unit is comprised of important electrical components that merge and runs the system.

6.What Is the Classification of Induction Cap Sealing Machine?

The classification of an induction cap sealing machine is described below:

BASED ON AUTOMATION

Manual Induction Cap Sealing Machine

Manual Induction Cap Sealing Machine -Picture Courtesy: Alibaba

This is an ideal machine for smaller production units or for laboratory applications that require manual handling by holding an induction cap sealing machine in hand and positioning it over the container to radiate an electromagnetic field. This machine offers a limited number of containers sealing each minute and per hour.

Semi- Automatic Induction Cap Sealing Machine

Semi-automatic Induction Cap Sealing Machine -Picture Courtesy Technopack

This machine offers to cater large production capacity per hour. Loading and discharging of containers required manual handling whereas remaining of the task can be performed by the machine itself. This type of machine is ideal for small to moderate production lines.

Automatic Induction Cap Sealing Machine

Automatic Induction Cap Sealing Machine- Picture Courtesy Alibaba

Running a large production line with high speed processing requirements prefer an automatic induction cap sealing machine as it can treat hundreds of jars/containers/bottles per minute and thousands of containers per hour. This machine is suitable for working day and night without the need for fixed supervision or manpower.

BASED ON WORKING

Capless Induction Sealing Machine

This machines is specifically design to seal the quality assurance of the product by applying an aluminium liner of helmetic seal without having caps over the bottle. The seal is temper evident and airtight applies on the mouth of the containers which helps to secure the product from tempering and contamination.

Continuous Induction Cap Sealing Machine

For high throughput production lines for packaging of products in batches, this machine is used for consistent quality sealing with lids. This machine has significance in industries with annual mass production.

7.What Is The Production Line Of Induction Cap Sealing Machine?

Bottle Unscrambler Machine

This machine is very useful in several packaging industries like pharmaceutical industries, beverage factories, and cosmetics. At high throughput production levels, the bulk of jumbled bottles need to be arranged in the correct orientation which enables to align them in the production line of packaging. This machine work by rotating disk and belts for the proper alignment of bottles. It is used in high speed packaging industries with mass production.

Tablet/Pill Counting Machine

It is most commonly used in pharmaceuticals, health care related industries mainly required to fill batches of containers with an accurate number of pills or tablets. This machine automates to ensure product accuracy and efficiency for fast packaging.

Desiccant Inserting Machines

This machine is mainly responsible to enhance the quality of the product. It is specialized to insert humidity-repellent pouches, most commonly used in pharmaceutical, food, and electronic goods to avoid moisture-sensitive products from damage.

Capping Machines

To secure the product, this machine intends to apply caps on the bottles/containers like screw-on caps, snap-on lids, and press-on caps, etc for quality assurance. This step is the first sealing step, in the next step caps are properly sealed to save the product for transportation and shifting of the batches. Improper capping can lead to contamination or leakage.

Induction Cap Sealing Machine

The application of aluminum foil seal or liner on the edge of the container is generated by heat in induction cap sealing machines. This machine works on the principle of induction heating to seal the mouths of the bottle to secure the product efficacy.

8.How Does Induction Cap Sealing Machine Work with Different Caps Sizes?

An automatic induction cap sealing machine is capable of sealing caps hooked to various sizes, on various heights and materials instantly.

This can be adjusted using the automatic controller or manually modulating the height of the sealing head by moving them up or down to the size of the bottle/container to achieve exceptional use.

Due to this flexibility, an induction cap sealing machine is enough to integrate with another machine for a variety of purposes for diverse formulation packaging and ensuring the fastest changeovers.

Plus, if you’re thinking about what cap’s diameter it can handle then most of the machines offering induction cap sealing with cap diameter size varies from 20mm to 120 mm or 7.87 - 47.24 inches.

9.What Types of Containers And Caps Are Compatible With Induction Sealing Machines?

An induction cap sealing machine is suitable and compatible with mentioned containers and sealing materials, such as:

TYPES OF CONTAINERS

PET Containers

Polyethylene Terephthalate can create lightweight and transparent bottles that are commonly used in storing food, beverage, and personal care products and can be compatible with an induction cap sealing machine with one piece or two-piece liners.

HDPE Containers

High-Density Polyethylene which is a highly durable and rigid plastic used for various purposes can produce effective sealing with an induction cap sealing machine and prevent leakage of product offering high packaging security.

LDPE Containers

Low-Density Polyethylene containers are flexible and can store produce that are used by squeezing the tubes or containers, such as kinds of toothpaste, lotions, etc., An induction cap sealing machine produces effective sealing with LDPE containers.

PVC Containers

Polyvinyl Chloride containers are absolutely cost-effective for storing various products used in medical supplies industries or food packaging companies. An induction sealing machine is highly compatible with PVC containers with particular sealing liners.

PP Jar & Bottles

Polypropylene plastic containers and bottles are highly popular for their high melting points. These jars and bottles are used in various industrial applications. An induction cap sealing machine is best known for its compatibility with packaging material composed of PP materials.

Glass with Plastic Caps

Products like jams, jellies, pickles, sauces, and spices, are commonly stored in glass jars; but their packaging is done by screwing plastic caps to make them induction cap sealing machine friendly for airtight sealing.

TYPES OF CAPS

One Piece Liner

It is a single-piece liner that is fixed in the cap and typically made up of foam or pulp joined with a layer of foil. This is best known for its cost-effectiveness and firm sealing.

Two-Piece Liner

This is mainly composed of two layers. One is backing material and a film seal. The backing material is made up of foam and pulp while the other layer is made up of film seal. This cap is suitable for air-tight and tamper-evident sealing.

Higher Barrier Version

This is a highly specialized form of cap liner which is made up of multiple layers of resilient materials that forms an effective barrier against the external environment such as chemical, or physical factor forming more stronger integrity with the bottle/container.

10.What is the temperature of the induction Cap sealing Machine?

Picture Courtesy- enerconind

The sealing head of an induction cap sealing machine is designed in a way that can induce heat temperature varying up to the type of material.

The material cap sealing layer made up of aluminum foil commonly requires a temperature limit of 185-350F to conduct heat and activates the heat seal inner coating.

A sealing head has an affinity to transfer heat radiation in the foil layer uniformly and evenly to prevent the liner's weakness or damage sealing.

As an electromagnetic field absorbs underneath the layer of sealing foil it tightly bonds with the container. After leaving the induction, once the sealing cools down the film’s hermetically seal can be seen when you open the cap of the bottle.

When the cap material is PET, HDPE, LDPE, and PVC, the observed sealing temperature ranges from 150 to 250°C.

11.How To Clean & Maintain Induction Cap Sealing Machine?

For cleaning and maintenance, you must follow the manufacturer’s guide to maintain the efficiency of the machine and prolong the life span. Following are some of the most important instructions for cleaning and maintaining the induction cap sealing machine.

Cleaning

Superficial residual removal	Always take a dry cloth for cleaning the exterior of the machine and be careful in cleaning the surrounding areas of the sealing head and control panel carefully
Safety Precautions	Before cleaning make sure all the electric connections are powered off
Sealing Head	There must be the use of soft and damp cloth, avoid the usage of abrasive clothes for cleaning the sensitive parts of the machine
Conveyer Belt	For proper cleaning, you have to remove the conveyor's belt according to the manufacturer’s instructions and clean it with warm soapy water and rinse it thoroughly and dry it first before reinstallation
Cooling System	From the prevention of overheating the cooling system has cooling vents and fans to make a proper airflow. It is important to remove the dust for their proper rotation
Electric connections	This is the most crucial part of cleaning where it is important to note any rust and wire damage from the connection of the machine to the main powerhouse board.

Maintenance

Regular Lubrication	It is highly recommended to make a chart of weekly checks on lubrication because it has a strong impact on the machine's functioning. All parts of the machine like the conveyor belt, moving trays and rotary pulleys, etc. must be greased at subsequent time intervals to maintain the efficiency of the machine
Replacement of Gaskets	Gaskets are the sealing liners between the containers and the caps. Keep on check for any damage, or crack on the gaskets and remove them once they are damaged.
Calibration	It is important to calibrate the machine periodically effectively to the sealing temperature and duration. Improper calibration can damage the packaging materials.
Maintain the Stock	According to the manufacturer’s guidelines, there is always an inventory list of the machine's spare parts to avoid any unexpected issues.
Professional Check	For the maintenance of the machine’s optimal performance, according to the manufacturer’s recommendations, there must be monthly visits arranged by the company for the professional technicians.

12.Is Induction Cap Sealing Machine the Same as Heat Sealing Machine?

No, although Induction Cap Sealing and heat sealing offering the sealing but the working use is different for the creation of sealing.

An induction cap sealing machinefollows the principle of electromagnetic induction for thermal radiation to form a tamper evident sealing. On the other side, a heat-sealing machine creates sealing with the help of high temperature heat sealers.

An induction cap sealing machinebonds the laminated material over the tip of the bottle via the non-contact method. This sealing is ideal to preserve the freshness, fragrance, and quality of the product inside the container without harming its integrity via heat radiation. Whereas the heat sealing machine works by contacting the sealing material.

An induction cap sealing machineneeds a conductive pathway to run electromagnetic energy and transfer movement of electrons to induce heat, such as aluminum foil those seals around the edges of the container. Whereas a heat sealing machine can be used for sealing a variety of materials such as paper foiled laminated goods, plastic film, bags, etc.,

An induction cap sealing machineis an advanced way of sealing whereas a heat sealing machine is comparatively more simpler version that can be used anywhere even in the kitchen for sealing bags.

When a container comes across an induction cap sealing machine; it produces sealing. Besides this,a heat sealing machine required pressure to seal the material, if pressure is insufficient to seal may fail.

13.What Technical Problems You Face with Induction Cap Sealing Machine?

An induction cap sealing machine can sometimes encounter technical problems; one must know how to deal with them. Below table is describing common faults as well as their corresponding solutions.

Problem & Cause

Solution

Picture

No Seal

This could be the result when the bottle passes through the sealing process but does not show sign of adhesion around it.

Causes

Insufficient Induction field.

Improper exposure time.

Insufficient or wrong induction liner.

Improper sealer running

Increase the Percent Output of the induction cap sealing machine.

Slow down the speed of the liner.

Check the alignment of the sealing head.

Weak Seal

When the bottle shows sealing but fails the pressure seal test.

Causes

Low output pressure and poor settings.

Inadequate exposure time.

Improper Sealing

Poor Toque

Increase Pressure Percentage OUTPUT of the induction cap sealing machine.

Determine the torque requirement of the bottle and closure.

Monitor and verify the alignment of the sealing head.

Burned Sealing

This can be checked when the seal liner shows discoloration or a wrinkled surface. That can also be determined by burned smell or a change in the taste of product.

Causes

Excessive exposure of induction heat field.

The improper head setting of the machine.

Excessive temperature and time exposure.

Verify and reset the OUTPUT % on the sealer.

Correct the alignment of the sealing head.

Reset exposure time and temperature.

Overheating or Underheating Problems

Machines mostly have a failure with sensors that results in these two problems.

Causes

Incorrect power setting.

Improper detection/sensor problem.

Re-calibrate the machine’s settings.

Reset the exposure time of the sealing zone.

Reset the speed of the conveyor belt to assess bottle exposure time.

14.What Things Should Be Considered When Purchasing an Induction Cap Sealing Machine?

Purchasing an induction cap sealing machine is a tricky experience, there are various things you must consider when looking for a purchase. Such as:

Determine your Need!

Consider your packaging needs and estimate your production capacity requirements per minute or per hour. Look at what type of packaging containers you use. Also, check what size caps you use and what type of material you deal with. Knowing your goals must be the first step to begin with your plan.

Pay Attention to the Machine’s Specification

Picture Courtesy- Wikipedia

Call your manufacturer or communicate with them via email to assess the manual and measure the machine’s specifications. Consider the workforce, your estimated budget, and the machine’s efficiency.

Your Area

Picture Industry- Kaps Industry

Estimate your lab size and the machine's width, height, and size when assembling with other units in order to achieve better installation and working conditions.

Competitive Vendor

Choose competitive vendors like Aipak Pharmaceuticals who always pay attention to consumer’s requirements and offer promising products and services.

Pre-Sale and Post-Sale Services

Good manufacturing companies always strive their best to offer excellent services whether pre-sale or post. You must know a good pre-sale service will allow you to get the right machine and post-sale services will ensure greater productivity.

Conclusion

For effective sealing, an induction cap sealing machine is the mainstay for major business firms ranging from food to health, household to agriculture. Thus, selecting the correct option can boost your investment. We hope this guideline has conveyed some very informative points about the induction cap sealing machine that you always look for. Allpack understands what a customer really needs to integrate into their packaging production line. We’re here to assist you! Please message us to open a gateway of discussion for future investment.

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Jar Filling Machine: The Complete FAQ Guide In 2025

Liquid Filling Machine

Jar Filling Machine: The Complete FAQ Guide In 2025

Have you ever felt curious about jar filling machine? This is an automatic equipment which is used to fill liquids into different containers such as jars, cans and buckets. To meet different filling demands, there are different types of jar filling machines on the market, which can fill containers of different volumes, among them, the largest volume can be measured in liters.

Can you tell that what aspects of the jar filling machine are you curious about? Its applications, classification, construction or working principle? Or, you are more interested in other questions? No matter what you want to know, in this article, you can get the most detailed introduction about jar filling machine. If you can't wait to learn this machine, please start reading.

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1.What is jar filling machine?

Generally speaking, jar filling machine is a liquid filling equipment, although it is called jar filling machine, it can also used to fill bottles and cans. This machine can fill fluid or semi-fluid liquids into jars quickly and accurately, it is widely applied in food, beverage, pharmaceutical, chemical, cosmetic industries, etc.

2.What are the advantages of jar filling machine?

Guess how can jar filling machine benefit you, using such an automatic machine, can largely increase your production efficiency. Want to know the advantages of jar filling machine? Let’s discuss together!

Increase Efficiency

As is mentioned that jar filling machine can increase your production efficiency, it can fill several jars at the same time, and the filling speed is fast, when these jars are full, the conveyor of the machine will deliver them away and replenish new empty jars. This methodical working process is much more efficient than manual filling.

No Wastage

During the filling process, the filling nozzles of jar filling machine will accurately align the mouth of empty jars, and they will enter the jars to fill liquids, as a result, the liquids will not splash out from the jars, which avoid wastage.

Improve Operation Safety

Why it is said that jar filling machine can improve the operation safety? On the one hand, the machine can provide precision filling, therefore, when filling some chemical liquids, it can prevent the liquid from splashing and touching the operator; on the other hand, the machine has emergency stop function, which is also a security.

3.What industries are jar filling machine applied in?

Jar filling machine can be used to fill all kinds of liquids so that it has a wide range of application, so, what industries are jar filling machine applied in? Here are some listed.

Food Industry

Jar filling machine can play a role in food industry, it is used to fill liquid products such as honey, ketchup, peanut butter, hot sauce, jam, tahini, beef sauce, chocolate sauce and so on. This machine can fill these products fast and accurate, and ensure the good appearance of the packed products.

Beverage Industry

Since the jar filling machine can be used in the food industry, it can of course also be used in the beverage industry. Even though most of beverages are packed by bottles, there are still some beverages are packed by jars, such as sparkling water and fruit wine, the jar filling machine is used to fill them.

Pharmaceutical Industry

In pharmaceutical industry, there are solid medicines and liquid medicines, jar filling machine can be used to fill liquid medicines into jars if there is this demand. For an instance, jar filling machine can be applied to fill syrup.

Chemical Industry

Chemical Industry-Photo Credit: Freerange Stock

Certainly, there are a lot of chemical liquids which have volatility, need to be sealed and stored, therefore, jar is a good choice to pack them. Jar filling machine can fill these chemical liquids into different jars, and make sure they will not splash out causing unnecessary accidents.

Cosmetic Industry

Cosmetic Industry-Photo Credit: Beauty Makeup Supply

Also, jar filling machine can be applied in cosmetic industry, there are many liquid and semi-liquid cosmetic products, such as lotion and cosmetic cream, this machine can fill them into different sized jars smoothly and efficiently.

4.What is the classification of jar filling machine?

According to different standards, jar filling machines can be divided to different types

According to degree of automation

(1). Automatic Jar Filling Machine

Automatic jar filling machine has high working speed and production capacity, it can deliver the empty jars to the filling station, and the filling nozzles fill the liquid product into the jars, when the filling process is finished, the machine delivers the jars away, in a word, the whole working speed is automatic, doesn’t need manual intervention.

(2)Semi Automatic Jar Filling Machine

Compare with automatic jar filling machine, the speed and degree of automation of semi automatic jar filling machine are lower. The machine can fill jars automatically, but the jars need to be fed and removed by a operator, therefore, the accuracy is relevantly lower than that of automatic jar filling machine. This machine is more suitable for small to medium production scales.

According to metering principle

(1).Overflow Jar Filling Machine

Overflow Jar Filling Machine-Photo Credit: NEOSTARPACK

Overflow jar filling machine works according to the liquid level, the filling nozzles fill liquids into the jars, once the liquid level reaches the set value, the filling is stopped. Therefore, the overflow jar filling machine can ensure that the height of the liquid in each jar is at the same level.

(2). Gravity Jar Filling Machine

Gravity Jar Filling Machine-Photo Credit: Liquid Packaging Solutions

The gravity jar filling machine fills liquids according to their weights, as the picture shows, there is a tank which is filled with liquids, when the machine begins working, the liquid is fed into the filling nozzles and filled into jars, when the quantitative liquid product is filled, the filling process is completed. Gravity jar filling machine is suitable for liquid with high fluidity.

(3). Pump Jar Filling Machine

Each filling nozzle of pump filling machine is connected with a pump which helps to fill liquids, pump filling machine is a good solution for those viscous, poorly flowing liquid products. Certainly, not only viscous liquids, pump filling machine can provide accurate filling for all kinds of liquid products according to volume.

(4) Piston Jar Filling Machine

Piston jar filling machine has a wide range of application, it can deal with think liquids and thick liquids, this machine can provide precise volumetric filling. Each piston jar filling machine is equipped with a cylinder, according to movement of the piston in the cylinder, the purpose of filling liquid is achieved.

5.What are the differences between jar filling machine and jar packing machine?

Differences between jar filling machine and jar packing machine-Photo Credit: ECHO Machinery & Pack Leader

The most essential difference between jar filling machine and jar packing machine is the purpose, the purpose of jar filling machine is to fill liquid products into jars, while the jar packing machine is to pack the products, therefore, the jar packing machine doesn’t only play a role in filling, it also complete the packaging and sealing process.

In addition, the scope of use of the two machines is different, although both jar filling machine and jar packing machine are used to fill various products into jars, the jar filling machine is mainly used to fill all kinds of liquid products into jars, while jar packing machine can pack powders, granules, liquids and many other products into jars.

6.What components consist of a jar filling machine?

In order to thoroughly understand a machine, you need to be able to simulate its workflow in your mind. How to do this? At first, you need to understand the structure of the machine, the structure of jar filling machine is as follows

Components of Jar Filling Machine-Photo Credit: SSP Manufacturing. Inc

Material Hopper: It is a storage tank which is full with liquid products.
Filling Change-over Valve: This valve is to control the material feeding, if the valve is opened, the liquid in the hopper will flow into the filling nozzle, on the opposite, the valve is closed, the filling is stopped.
Filling Nozzle: The function of this part is to fill liquid products into empty jars.
Touch Screen Control: You can turn on/off the machine and set up all parameters on this touch screen.
Guard Rail of the conveyor: This part let the jars move on the correct track.
Jar Mouth Positioning Device: This part is to fix the jar during the filling process, which ensure the accuracy of jar filling machine.
Conveyor: Conveyor plays a role in delivering, it feeds empty jars to filling nozzles, and moves them away after filling.
Front & Back Jar Stopping Device: Once the empty jars move to the correct position, the two jar stopping devices let these jars stop.

7.How does a jar filling machine work?

Now, it’s time to learn the working principle of jar filling machine, do you know how does the machine work? It doesn't matter if you don't know, let's learn it together.

At the beginning, the empty jars are loaded on the conveyor of the jar filling machine, and then the conveyor begins moving and delivers the jars into the filling station. When the jars are moved to the destination, they are stopped and fixed, and then the filling nozzles are aligned with the mouths of jars and then enters them.

At this moment, the filling valve is opened so that the liquid product in the hopper is flowed into the filling nozzles and filled into the empty jars. When the jars are full, the filling operation is stopped and the filling nozzles return to their original position, the filling valve is closed, and there are other jars conveyed here, the above steps are then repeated.

The filled jars are moved to the next station of the whole production line, however, there is a type of machine which is called jar filling and capping machine, it can not only fill liquid product into jars, but also can seal the filled jars. In this machine, the filled jars are conveyed to the capping station and capped.

8.What factors can affect the filling speed of jar filling machine?

Although jar filling machine has a fast speed, there are also some factors may affect the speed of it, they’ll be introduced to you next.

Product Viscosity

The basic factor which may cause influence to the filling speed of jar filling machine is the product viscosity. It is important that which kind of liquid you want to fill with a jar filling machine, the more viscous the liquid, the greater the density, the slower the flow speed, so the filling speed of the jar filling machine is also slower.Conversely, if it is a fluid, less viscous liquid, it will have little effect on the filling speed of the machine

Container Volume

As you know that there are a lot of jars which are in different shapes and sizes, another important factor which will affect the filling speed of the jar filling machine is the container volume. The reason is very simple, in the same time, is it faster to fill a small jar or a larger jar? The answer is of course the small jar.

The Condition of the Machine

To be honest, the condition of the machine itself is also important, the moving parts will be worn after long-times using, therefore, if the components of the jar filling machine are old, the filling speed is naturally low. Therefore, it is a good behavior to check and replace machine parts regularly.

9.What kinds of products can be filled by jar filling machine?

Generally speaking, basically most of the liquid materials on the market can be filled by jar filling machines, such as:

Food products: The food products which are in liquid form, such as ketchup, oyster sauce, soybean paste, hot sauce, salad dressing, mayonnaise, jams, chocolate sauce, etc.
Drinks: The most common liquid products are drinks, the industry uses jar filling machine to fill a lot of drink into jars, which include juices, carbonated drinks, drinking water and so on.
Dairy products: The most common jar packed dairy products are milk and yogurt.
Wines:All kinds of alcohols, including wine, liquor, beer, can be filled by the jar filling machine.
Chemical products: Many chemical products, such as flammable solvents, acids and corrosive products, paints, petroleum, which can be filled in jars and cans, are compatible with jar filling machine.
Pharmaceutical products: Jar filling machine can be used to fill all kinds of liquid medicines, including various oral solutions, suspensions and topical drugs.
Cosmetics: Jar filling machine can fill a lot of cosmetics, such as face cream, moisturizing lotion, perfume, essential oil, shampoo, etc.
Personal care products: Although relatively rare, there are actually some personal care products that are packaged in jars, such as shampoo, shower gel, body lotion, hair conditioner, etc.

10.What containers can be filled by jar filling machine?

In fact, jar filling machine can be compatible with many different containers, are you curious about them? Keep on reading to learn them.

Bottles

Bottles

Although jar filling machine is designed for filling jars, it can also used to fill all kinds of bottles, which include plastic bottles and glass bottles, and the filling accuracy is still high.

Jars

Jars

Jar filling machine can fill liquid products into various jars, regardless of shape, size, tall or short. In general, plastic jars and glass jars are more common on the market, the jar filling machine can fill different liquids into these jars according to different filling requirements.

Cans

Cans

It may be a little amazing, but, that there are plenty of jar filling machines which have high production capacity and filling volumes, are compatible with cans. Jar filling machines can fill liquid products into large and small metal cans.

11.What are the auxiliary equipment of jar filling machine?

Naturally, only a jar filling machine can not complete all the packaging processes. Then, what auxiliary machines does the jar filling machine have? Next, let’s learn them one by one.

Bottle Washing Machine

Bottle Washing Machine-Photo Credit: IC Filling Systems

The first one to be introduced is bottle washing machine, as you can guess from its name, its main function is to clean the empty jars, besides cleaning, this machine also plays a role in disinfection. Bottle washing machine is suitable for all kinds of containers, in the production line, this machine is in front of the jar filling machine, the jars are cleaned and delivered to be filled.

Bottle Unscrambler

Actually, in the whole production line, there is a machine between bottle washing machine can jar filling machine, that is bottle unscrambler. When the jars are cleaned and sanitized, they are conveyed to the bottle unscrambler, which can organize and arrange them neatly for easy delivery.The bottle unscrambler and the jar filling machine are connected by a conveyor, the sorted empty jars are conveyed to the jar filling machine in an orderly manner, waiting for filling.

Capping Machine

After introducing the machine which are before the jar filling machine, let’s introduce the machine after it. When the jar is filled with liquid, what is the next step, of course, is sealing, so the capping machine is here to complete this operation. When the jars are full, they are delivered to the capping machine, then the machine will apply caps to them and seal them.

Labeling Machine

The final step of the production line is labeling, the liquid products are packaged into jars for sale, so it is necessary to label them so that customers can learn their detailed information. Labeling machine is the next station of capping machine, when the jars are filled by jar filling machine and capped by capping machine, they are conveyed to labeling machine and labeled. At this moment, the whole packaging process is finished.

12.Can jar filling machine be upgraded? And how?

Yes, of course that jar filling machine can be upgraded, if you want to increase your production capacity, it is necessary to upgrade your jar filling machine. But, how can you upgrade the machine? Generally speaking, there are actually two methods, one is to upgrade the existing parts of the machine, and the other is to add additional filling nozzles.

Main Parts Upgrade

Technology is always being updated. If there are advanced components are introduced on the market, you can replace some of the existing components of the jar filling machine and make some upgrades. This operation is to prolong the service life of the machine, and on the other hand, it is also to keep the machine advancing with the times and not be eliminated.

Add Additional Filling Nozzles

If the last step is to upgrade the whole jar filling machine, this step is to upgrade the production capacity of the machine. The production capacity of the machine is fixed if you don’t make changes. However, when you add additional filling nozzles, the machine can fill more jars per turn, so there is no doubt that the production capacity is improved.

Conclusion

So far, how much do you think you know about jar filling machine? At least, you should now know what this machine does and how it works. The jar filling machine is commonly used in various industries and it can bring you a lot of benefits. Are you considering a jar filling machine into your business? If you are, you can consult us at any time, we’ll solve your problems at once.

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Desiccant Inserting Machine: The Complete Buying Guide in 2025

Desiccant Inserting Machine

Desiccant Inserting Machine: The Complete Buying Guide in 2025

Is it possible to put desiccant manually in hundred bottles each minute? Certainly not!

A desiccant inserting machine is a superb technology that emerged through mechanical engineering that controls thousands of bottles for the fastest desiccant insertion each hour. Therefore, your product can be safe against humidity for a longer time. This machine is not only responsible for safeguarding delicate formulation but offering you high efficiency and profitability. Do you know how it works? What important components are responsible for its integrity and excellent functionality? How can it help to improve your production line? Please read this guideline carefully prepared to answer your all questions. Let’s get started it!

Add a header to begin generating the table of contents

1.What Is Desiccant Inserting Machine?

This is an advanced machine designed to place a desiccant inside the packaging material that ensures the packaging product is intact and fresh against moisture. Because desiccant is responsible to trap moisture inside packaging container and protects the progression of degradation. By this way, you can retain potency and efficacy of your active product during transportation or storage for a longer time.

Previously, manual method was used to keep desiccant inside natural products like sugar, salts, Over time industries brought revolutionary way by using automatic desiccant inserting machine that has emerged in modern industrial sector as the most robust and time saving option.

With the help of sensors, conveyor, and touchscreen mechanism; it can ensure hundreds of desiccant placements with low chances of human error as well contamination.

2.What Is the Industrial Purpose of Desiccant Inserting Machine?

The industrial applications of a desiccant inserting machine are broad and diverse. This is because moisture absorbents play important role products safety. Some of major industrial uses are as followed:

Pharmaceutical Industry

Picture Courtesy-Abrifete

The significance of a desiccant inserting machine cannot be overlooked when it comes to storing and transporting medicines. The presence of desiccants is involved in maintaining the potency, quality, and safety of sensitive pharmaceutical products against degradation. For example, gelatin capsules, tablets, effervescent tablets, etc.,

Food Industry

Epicurious

When it comes to preserve the freshness and taste of food products; a desiccant inserting machine play a significant role to maintain product’s shelf life by preventing microbial growth or preserving the nutritional values. For example, dried fruits, ready to use chapatis, spices, cereals, grains, etc.,

Chemical Industry

Nutraceutical Industry

The nutritional supplements are the sensitive category of oral dosage forms that are composed of essential and non-essential vitamins, proteins, trace elements, minerals, probiotics, and other important compound that can boost well-being. Indeed, moisture can deteriorate integral elements of these supplements; a desiccant inserting machine is of prime important in this industry as it offers you an easy and fast solution of placement desiccant in each packaging respectively.

Cosmetic Industry

The manufacturing of face serum gelatin capsules, face powders, eye powders, and hair products, are always prone to degradation in the presence of moisture content. A desiccant inserting machine is a useful equipment for inserting desiccant bags to protect these products against moisture.

Electronic Industry

Picture Courtesy- Aquauk

This industry deals with a broad spectrum of electrical components made up of steel, iron, nickel, etc to make tools like switches, circuit extension boards, nuts, etc. Inside their packaging pouches, a desiccant inserting machine is worth buying the machine in this sector as a moisture absorber can avoid humidity to save the product from corrosion.

Agricultural Industry

Picture courtesy- Amazon

A desiccant inserting machine is used in the agricultural industry for the packaging of seeds, grains, dried flowers, pollens, etc., these substances are used for germination procedures to progress the development of the crop. So, a desiccator inside is recommended to avoid moisture content and improve the ideal condition.

Optic Industry

A desiccant inserting machine is used to put desiccant in the packaging bags of contact lenses, glasses (sun glass, vision glass) to avoid moisture content and protect against moisture content that affects the surface of the glass or induce lenses stickiness.

Pet Food Industry

This industry is a large manufacturing sector for producing pet food to maintain health by offering good nutritional values. These products include nuts, beans, cereals, grains, vitamins, and minerals that must be moisture-free. A desiccant inserting machine is highly recommended and used during the packaging procedure of these products.

3.What Are the Benefits of a Desiccant Inserting Machine?

A desiccant inserting machine is a popular and useful machinery that has rapidly replaced manual handling of inserting desiccant as it offers unlimited benefits to your business. Some of them are discussed below:

Offering High Speed and Quick Operation

A desiccant inserting machine has solved the hectic methodology of manually inserting each strip inside each individual pack. A high speed and quick operation ensure catering to high production capacity in no time that leading to improve productivity and profit.

No Chance of Product Damage or Leaked Desiccant Strip

The machine can accurately cut every ending of the strip so it can perfectly place inside without any chances of desiccant leakage or entrance silica gel beads in your product.

Stainless steel Body Structure

The machine makeup is entirely based on stainless steel which ensures super hygiene with no chances of cross-contamination or microbial growth.

No Laborious Work

An automatic system for long term processes can reduce labor costs and continuous supervision or handling. This machine can ultimately save costs in all aspects.

Perfect Integration with Other Machines

The machine can seamlessly integrate with other machines of the production line without any replacement or modification of the facility setup.

4.What Is Working of The Desiccant Inserting Machine?

The working principle of a desiccant inserting machine is super-easy. Please follow our step by step working principle with easy illustrations.

STEP 1- Feeding

Feeding

At this stage, whether a container, bottle, jar, or pouch, comes inside the machine with the help of a conveyor that loads them in one go. This pathway helps in positioning the packaging material towards its exact position where a desiccant has to be loaded.

This is another major step where a loaded desiccant is ready to supply into the packaging with the help of a rotating desiccant supply unit. These desiccants are designed in such a way that each packet goes directly into individual products respectively.

A desiccant inserting machine is equipped with shear knives for the purpose of separating each desiccant strip from the series of loaded sheets or films. When an object faces the desiccant inserting zone, the sensor detects the presence and cuts the strip automatically cut them.

This is an important step which is closely similar to the cutting step. Upon subjecting the bottle right to the desiccant zone; the machine senses the presence and positions each unit of desiccant into it. ., The following step assures you have put desiccant which is ready for insertion without any damage or leakage.

This is the step that allows corrected bottles with desiccant inside to be ready to leave the machine and can continue to enter along the production line for the final procedure. Upon the type of packaging material, it can pass through a series of steps such as sealing machine, labeling, etc.,

5.How To Classify a Desiccant Inserting Machine?

A desiccant inserting machine presents the following classification:

ACCORDING TO MACHINE HEADS

Single Head Desiccant Inserting Machine

Picture Courtesy: countec

A single head desiccant inserting machine is a specialized design used for inserting unit desiccants into packaging material such as sachets, bottles. This is the compact and cost-economical option to approach modern way of packaging. This is a robust machine that utilize the single head for desiccant film roll suitable for small to moderate capacity production facilities.

Dual Head Desiccant Inserting Machine

Picture Courtesy: countec

A dual head desiccant inserting machine is an excellent machine used to cater to large production capacities. This machine is equipped with dual unwinding desiccant heads with dual cutting knives and features more extensive options that can simultaneously perform the best and fast operation in a short time. This machine can deal with hundreds of bottles per minute with 100% accuracy. A sensor ensures the entire procedure is perfectly run through exactness and transported product is correct for further steps.

ACCORDING TO DISPENSING UNIT

Vertical Desiccant Inserting Machine

Picture Courtesy: Made in China

This machine is ideally designed for overwrapping film pouches, or film form sealing machines where the hopper dispenses the desiccant unit vertically. This structure works when containers or pouches are subjected to an upright position where their primary facing orientation is straight or vertical. This machine is commonly used in the food pouch packaging industry.

Horizontal Desiccant Inserting Machine

Picture Courtesy: Made in China

A horizontal desiccant inserting machine is designed to insert desiccant units into containers. The following machine works on a continuous pattern to offer seamless operation with high accuracy.

ACCORDING TO MECHANISM

Vibratory Trays Desiccant Inserting Machine

Picture Courtesy: Bellatrex

This machine inserts desiccants inside the packaging material with the help of vibratory trays that are designed with multiple channels that assist the way toward the container, bottle, pouch, etc., These trays vibrate in a gentle way to align the desiccants and ensure the control over the procedure.

Simple Desiccant Inserting Machine

Picture Courtesy- Youtube

This machine is commonly used standard way of desiccant insertions into each packaging material. This machine follows a straightforward procedure that works by directly cutting of strips and their insertion into each packaging material without any steps or complicated mechanisms.

ACCORDING TO DESIGN

Rotary Desiccant Inserting Machine

In the rotary desiccant inserting machine, bottles move seamlessly around the desiccant inserting zone via a circulatory turret or carousel. The empty bottles rotate where desiccants are entered and leave the system along the rotary pathway. This machine is used for fast and high-speed production processes that give you high output.

Linear Desiccant Inserting Machine

In this machine, all the packaging material comes in contact with the desiccant insertion zone in a linear fashion. This follows semi-automatic or automatic functioning where the process is taken place gently throughout the pathway which is a suitable option for medium to large production batches.

ACCORDING TO AUTOMATION

Semi Automatic Desiccant Inserting Machine

semi-automatic desiccant inserting machine- Picture Courtesy CVC

A semi-automatic desiccant inserting machine requires the involvement of the operator in running some steps such as loading empty containers for desiccant insertion, whereas once they’re fed onto the conveyor it combines the automatic running via insertion of desiccant inside. After placement of the desiccant, the machine delivers the container via a conveyor which is removed manually. This machine is suitable for medium production systems where hundreds of bottles can be treated each hour.

Automatic Desiccant Inserting Machine

Picture Courtesy- Alibaba

This machine works fully automatically where a set of containers comes in contact with desiccant placement and leaves itself without the requirement of manual handling. An automatic desiccant inserting machine is an ideal machine for a production area running a huge capacity of containers. Because this machine offers a consistent work throughput with gentle placement of desiccants under high speed.

ACCORDING TO MOTION

Intermittent Desiccant Inserting Machine

This machine is designed with a special feature in which the desiccant inserting machine places the desiccant bag or strip inside the container in Start-Stop motion or following intermittent motion. This machine is an economical device that can ideally cater to small to medium production lines.

Continuous Desiccant Inserting Machine

Here, the mechanism of the desiccant inserting machine follows a continuous motion with no Start-Stop working principle ultimately ensuring a seamless movement of the production procedure.

6.What Is the Mechanical Structure of a Desiccant Inserting Machine?

Desiccants are available in two types i.e. pre-cut pouches and canisters. Some desiccant-inserting machine work with single types while other models can be used to insert both types. Some important parts of the desiccant inserting machine are given below however, one should always consult the machine manual for an accurate description and working of the machine.

Part	Description	Picture
Roller	Some desiccant inserting machines have rollers instead of hopper where rolls of uncut desiccant are hung up. As the rollers move the desiccants are conveyed into the machine.
Shearing knife	Before delivering the desiccant to the counter a highly precise knife cuts at the edge without damaging the desiccant. The desiccant then moves toward the counter via a vibratory tray.
Hopper	This is the unit where pre-cut pouches or canisters are held. Machine equipped with hoppers do not required shearing knife or rollers. Many manufacturers offer models that accommodate either orientation.
Vibratory tray	From hopper individual desiccant are moved towards the counter via vibratory tray. The movement and separation of the desiccants is due to continuous and vibratory motions.
Counter	Most automatic machines have infrared sensory counters that detects desiccants and releases single desiccant in the bottle below the chute.
Chute	Chute delivers desiccant inside the bottles.
Rotary wheel	A rotary wheel orientation is most commonly desired when high production capacity is required. A rotary wheel simultaneously deliver number of bottles below the chute for release of product.
Conveyer	Conveyer system is usually consisting of infeed, outfeed conveyer, pulleys, belt etc. Conveyer system is controlled by a three phase motor and can be operated via control panel.
Control panel	Control panels in most automatic units have a touch screen display through which the entire operation is carried out. From machine parameters to machine function, all are operated and displayed on the screen.
Detection system	The desiccant inserting machine is equipped with top notch infrared sensors that not only detect and release desiccant into the bottles but also remove unfilled, inverted, and dropped bottles from the conveyor.
Removal mechanism	The system detects and removes any unfilled bottle from the assembly by simply changing the path of the bottle. Once the bottle is removed the diversion is automatically cleared and the outfeed is continued.

7.What Types of Products Are Supported by A Desiccant Inserting Machine?

Desiccant inserting machines can support multiple products in terms of packaging. These products are enlisted below:

Bottles	Desiccant inserting machine is ideal for processing all types of plastic and glass bottles with ranging size. These bottles may contain medicines, candies, bubble or gummies etc.
Jars	Jars made up of glass or pottery can also be processed by this machine. They are mostly used for storing food like biscuits, snacks and other types of dry food to prevent moisture.
Pouches	Pouches are moisture resistant storage packages made with plastic and a thin layer of aluminum foil to resist ultraviolet light. However, most of the pouches still contain silica gels for additional care. Therefore, a desiccant inserting machine is used to carry out this task.
Sachet	Similar to pouches, sachets are also made from plastic, but they are small in size and having little space for storage. A desiccant inserting machine is capable of doing the same task for sachets too.
Cans	Cans are rigid and compact storage containers derived from metal. Most of the susceptible and sterile goods are stored in cans to give extra protection, hence, they are filled with desiccant by this machine.
Tubes	You may have an experience using effervescent tablets which are packed in large narrow tubes made of flexible plastic having a silica bag inside it. This excellent experience is indeed the result of desiccant inserting machine which processes it responsibly.
Cartons	Cartons are small corrugated boxes made from paperboard. These cartons are used for a variety of purposes such as packing food items, jewelry, home accessories or glass, etc. Therefore, reputable industries used to process supply their customers with the best products unaffected by moisture, for which they use a desiccant inserting machine.

8.What Production line does a Desiccant Inserting Machine Support?

The Production Line of Desiccant Inserting Machine Support

Bottle Unscrambler	In the first step, this machine is mainly responsible to arrange empty bottles in a proper alignment in order to correct orientation. This can help to maintain a smooth flow in the production line, particularly at the upright position.
Pill/Tablet/Capsule Counter Machine	As the name suggests, this machine is efficient in counting pills/tablets and dispensing in the bottles accurately with surety to product uniformity and a correct number of pills.
Desiccant Inserting Machine	This is the focal point of the production line, which is highly important for product safety by inserting moisture-repellent pouches in each bottle accurately.
Capping Machine	After completion of product fillings, these bottles are properly secured with caps or lids. The capping machines are highly automatic with tightening of the caps for safety particularly in storage and transportation.
Induction Sealing Machines	These machines tend to provide airtight seals by generation of heat with an extra layer for the protection of the bottles from tampering and maintenance of the product freshness. It reflects the quality of the product.

9.How to Maintain the Desiccant Inserting Machine?

Picture Courtesy- Made in China

This is essential to take care of your machine on a regular basis to ensure it gives a good performance and extended shelf life. There are some maintenance points you must follow to achieve better results.

Maintenance	Description
Daily	A visual must be done regularly after the operation to determine loose components or abnormalities. Using compressed air, a dry cloth, and a brush can help you in proper cleaning of debris or dust around every corner of the machine.
Weekly	All moveable components of the machine should be treated with lubrication to avoid friction. For example, conveyor belt, cutting knives, rotary desiccant dispensers., etc. Check and replace worn out parts of the machine.
Periodically	Reset the setting of the machine using PLC. Delete old file for fast response of the touchscreen system. Check the interior electrical component of the machine and replace wiring, damaged parts if needed. Lubricate the movable joints for smooth functionality.

10.What are the Technical Problems and Solutions of Desiccant Inserting Machine?

While using desiccant inserting machine, you may face some challenges which can lead you to bigger problems. To enable you to solve these issues, the table below will be helpful:

No	Problems	Causes	Solution	Picture
1	Instead of cutting the edge, the blade cuts middle of desiccant	It is due to inaccurate setting of distance between each desiccant bag	Adjust the length for each desiccant bag by using touch screen panel
2	The problem of inaccurate desiccant cutting remains after setting of distance	If you are using marking based sensor cutting then there may be double mark on desiccant bag	Make sure to use blank bags for desiccant. In case of printed bags, keep the color of targeted area distinguish
3	Rollers show resistance while pulling desiccant	It occurs when rollers are too much dry, thus, result in friction	Keep the rollers and wheels lubricated to prevent surface resistance
4	The edges of desiccant bags are roughly knives	It may be due to untidy or blurred cutting blade	Clean the blade by removing residues and replace it with new one if blunt

11.What Points to be Considered Before Purchasing a Desiccant Inserting Machine?

Discussed below are the points one must keep in mind when purchasing a machine.

Size and Packaging Type

Do you run a packaging line with large sizes? You must see if the selected machine offers to insert desiccant strips with various sizes and can accommodate fully different containers.

Production Capacity

Are you Planning to Run Faster Production? You must determine your planning goals such as expected production capacity as well as the number of desiccant insertions in each cycle. This would help you to choose whether you need a small, medium, or large machine.

Automation

Picture Courtesy- Alibaba

Are you affiliated with limited production? For that buying an automatic desiccant inserting machine is not a wise decision. You can determine what production output per hour you need and what automation is suitable for your purpose. If you have limited labor resources then go for automatic, if you have a limited budget go for semi-automatic.

Flexible Integration

Picture Courtesy: Lenis Machine

You must know future machines can seamlessly be compliant with other existing machine and allow flexible integration with them.

Installation Area

Picture Courtesy: Bellatrex

You must determine production flooring and facility area specification in order to adjust your machine perfectly. Larger machines in congested areas cannot be accommodated and may affect its efficiency later.

Conclusion

In conclusion, a desiccant inserting machine plays a significant role in maintaining product stability, freshness and shelf life. By placing a desiccant inside the packaging containers can effectively enhance the protection and minimize the chances of developing moisture content. That’s why machine is preferred in contributing high role in various industries. Planning to Purchase? Contact us now for more guidance and details.

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WhatsApp Us: +86 181 7101 8586

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Want to get Best Price Desiccant Inserting Machine from China?

Tell us your material or budget, we'll reply you ASAP within 24 hours

Desiccant Inserting Machine: The Complete Buying Guide in 2025 Read More »

Stand Up Pouch Machine: The Complete FAQ Guide In 2025

Doypack Machine

Stand Up Pouch Machine: The Complete FAQ Guide In 2025

Stand-up pouches or doypack can be seen everywhere in our life. Are there any products in your life that often use this kind of packaging? Do you know why the stand-up pouches are so popular now? Do you know what kind of machines are designed for this kind of packaging? All the details about this packaging and packaging machine will be cleared out in this FAQ guide. Let's enjoy!

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1. What Is The Stand Up Pouch?

A stand-up pouch or doypack is a type of flexible packaging that is able to stand erect on its bottom for display, storage, and convenience. It is a common packaging way that is widely applied in all kinds of industries.

The stand-up pouch or doypack is very common in our life. Especially when this kind of packaging is applied to the food industry. In different industries, the materials used in the stand-up pouch are also different. In the food industry, this packaging is generally applied with non-toxic, tasteless, healthy, and environmentally friendly materials.

2. What Are The Types Of Stand Up Pouches?

All stand-up pouches have different purposes and characteristics:

Bottom Gusset Pouches

The bottom gusset pouches are stand-up pouches with an oval-shaped base. It can facilitate the storage and display of products. Generally, the bottom gusset pouch can be designed with windows for view, handles for control, tear notches for your opening, and valves for degassing.

Side Gusset Pouches

The side gusset pouches are designed with side gussets to give you a generous front and back printing area and display space. Thanks to its multi-layer design, it can greatly prevent your products from moisture, steam, and light.

Flat Bottom Pouches

The flat bottom pouches are designed with a rectangular base, which not only supports long and secure standing and displaying but also provides you with five printing sides. Another feature is its durability. The flat bottom pouches are reinforced at the bottom to accommodate more weight.

Retort Pouches

The retort pouches are stand-up bags with rounded bottom gussets. It is a packaging bag specially used for packaging aseptically processed products. Its main feature is that it is portable and easy to open. The retort pouches are specially used for packaging field rations, space food, fish products, camping food, instant noodles, etc.

Spouted Pouches

The spouted pouches are suitable for filling various free-flowing liquids and fluid products, such as liquids, beverages, creams, gels, solvents, powders, etc. Generally, its top and side position are installed with a spout, which is convenient for you to pour out without any leakage.

3. What Are The Types Of Sealing Mouth For Stand Up Pouches?

There are plenty of sealing mouths for your choice:

Zipper Grip Seals

A zipper grip seal is the most common sealing method in stand-up pouches. It consists mostly of a simple plastic ridge. By nesting the different tracks in the plastic ridges into each other, the closure can be held tightly together. This kind of sealing is simple, cheap, and effective, and is very popular among manufacturers.

Zipper Slide Seals

The zipper slide seals help you open and close the seal quickly and securely, with minimal effort. This packaging method provides you with a tight, reliable product package. But its cost may be more expensive than ordinary sealing.

Spout Seals

The spout seals are mostly applied on the spout pouches at the top or side of the pouch for easy dispensing of liquids and creams, etc. They are all premade bags and can not apply for the granules filling and sealing.

4. What Materials Are Stand Up Pouches Made Of?

The materials by stand-up pouches are usually made of multi-layer materials such as plastic films, paper, foil, etc. These materials are made of high-quality barrier films and can prevent the ingress of moisture and oxygen. Some metal packaging bags also have the function of avoiding light and deodorizing.

Laminated Film

The laminated film is made of two or three layers of film after bonding and heat pressing. This film is widely used in various packaging fields, especially in the field of food packaging. It's safe, reliable, and the material can withstand the printing of high-impact graphics and labels.

Laminated Paper Film

The laminated paper film can be widely applied for product packaging in the pharma and health care, food, and beverages industries. This material is very environmentally friendly, can effectively prevent moisture and light, and can be used in almost all food packaging.

Aluminum Foil Film

The aluminum foil film can be used for the packaging of many kinds of food, such as candy, biscuits, sausage, dried fruit, raw and cold cooked food, etc. This material has strong heat resistance and high-temperature resistance and can accept colorful printing.

5. What Are The Advantages Of Using Stand Up Pouches?

Compared with other packaging bag types, including pillow pouches, sachets, etc., the advantages of stand-up pouches are very prominent:

Special Bottom Style

Compared with other types of pouches, the stand-up pouches can provide you with solid support of the special bottom design, whether it is for display or for easy access, this design is great. And it can also provide you with a large capacity of space.

Durable

Durable

Stand-up pouches are generally made of extremely durable materials, strong and reliable. It is not easily torn or punctured. Even storing some sturdy items such as walnuts will not be a problem.

Sustainability

Compared with traditional hard packaging, the current stand-up pouches are more environmentally friendly. Because this packaging uses more environmentally friendly materials and manufacturing processes in the production process, it can save more resources and reduce waste.

Product Secure

The high-quality packaging material of stand-up pouches can well ensure that the contents avoid contact with air and dust, thus extending the shelf life and freshness of the product.

Low Cost

Stand-up pouches are more expensive to make than regular bags, but far less than boxes or bottles. But it can achieve the same packaging effect as a box or bottle. This can greatly save the packaging cost of the product.

6. Stand Up Pouch VS Flat Pouch

Before comparing a stand-up pouch and a flat pouch, we need to understand what is a flat pouch.

Flat Pouch

Contrary to the stand-up pouch, the flat pouch doesn't have any gussets, bottom seals, etc. A flat pouch is generally a back seal or a three-sided seal. Due to the simple design of this bag, it is relatively cheap to make and is widely used without the same.

	Stand Up Pouch	Flat Pouch
Appearance
Bag Design	Special bottom design with gussets that can stand up on the shelf.	Without a special bottom design that is designed lay flat.
Bag Types	Bottom gusset pouches, side gusset pouches, flat bottom pouches, retort pouches, spouted pouches.	Sachets, pillow bags, three-side seal bags.
Product Types	Suitable for packaging products with high volume or bulk quantities.	Suitable for packaging products that are slim and can neatly fit inside a tray or box.
Purpose	Can stand directly to display at the shelf to attract customers.	Unable to stand, often displayed on hooks to attract customers.
Size	There are a variety of sizes, and the inside space is also large, just need to choose according to the number of products.	There are a variety of sizes, but the inside space is not particularly different, and it needs to be selected according to the tight fit of the product.

7. What Is The Stand Up Pouch Machine?

The stand-up pouch machine also referred to as doypack machine uses premade stand-up pouches or doypack to fill and seal all kinds of products. This kind of machine has a very large production capacity, and most of them are fully automatic design. It can even provide you with a very large capacity filling line.

8. What Products Are Often Applied By Stand Up Pouch Machines?

The stand-up pouch machine is widely used, most of which are concentrated in the pharma industry, skincare, food and beverage industry, and chemical industry.

Food and Beverage

The stand-up pouch machine can be used to fill powder, liquid, fluid, and solid, almost all hardness products are applicable. Foods that are often filled include sausages, nuts, dry food, snacks, cheese, preserved fruit, fruit, flour, powder seasoning, etc. Liquids include sauce, rice vinegar, fruit juice, tomato sauce, peanut butter, jam, paste, etc.

Pharma Industry

Many nutritional supplements, pharmaceutical raw materials, protein powder, vitamin gummy, gauze, band-aids, traditional Chinese medicine, liquid supplements, etc. are using this stand-up pouches packaging.

Skin Care

Face cream, body lotion, laundry detergent, hand soap, shower gel, shampoo, hand cream, essence, dish soap, facial cleanser, sunscreen, hair conditioner, etc. are all widely used in stand-up pouch machines.

Chemicals

Various chemical and industrial raw materials can be packaged using stand-up pouch machine. These include pigments, coatings, talc, paints, cement, fertilizers, and more.

9. What Are The Advantages Of Applying Stand Up Pouch Machines?

After applying the stand-up pouch machine, you can get the benefits of:

Flexible Packaging Application

The stand-up pouch machine can be used for filling and packing different liquid, paste, and cream products such as water, oil, milk, juice, ketchup, tomato sauce, peanut butter, honey, mayonnaise, liquid detergent, shampoo, body washing, and other non-free-flowing liquid when equipped with different filling machines like piston pump filling parts.

High Speed And High Capacity

The stand-up pouch machine generally adopts a fully automatic mode. You can choose the mode of premade pouch or film bag making according to your needs. Both modes don't slow down your productivity and can bring high efficiency.

Easy Operation And Maintenance

With the fully automatic mode and the PLC control, you only need to train one employee to operate the machine according to the manufacturer's instructions. And most of the machines have an automatic cleaning function, which is very convenient for your early use and later maintenance.

High Automation

The whole process of the stand-up pouch machine operation does not require human participation, only one supervising staff is required. This can drastically cut your labor costs.

10. What Is The Working Principle Of Stand Up Pouch Machine?

The stand-up pouch machine works as follows:

Working Principle Of Stand Up Pouch Machine -photo credits: Acepack

Film Unwind. Once the machine has been started, the films will be unwind for the stand-up pouch making later.
Bottom Hole Punching. To control the humidity and the amount of oxygen inside the bag, before the bag forming, the films will be punched for the bottom hole.
Bag Forming. The ends of the film roll are aligned and rolled up. The approximate shape bag has been formed.
Film Guide. The film guide is to fix the shape of the bag and facilitate further plastic and heat sealing later.
Bottom Seal. A special mold is applied under the bottom seal to mold the bottom of the bag into an oval shape or rectangular shape to make them stand up.
Vertical Seal I. The heat seal panel will heat seal the left edge of the bag.
Vertical Seal II. The heat seal panel will heat seal the right edge of the bag.
Tear Notch. Two tear notches will be cut on the edge of the top side of the bag that has been heat-sealed on three sides, which is convenient for customers to open later.
The photocell will locate the position of the bag.
Servo Advance. Servo advance keeps the bag going.
It separates the pouches from the films.
Pouch Catching. After each pouch has been separated from the films, it will be caught and controlled for the following steps.
Pouch Opening. The grip will open the top mouth of the stand-up pouches.
Air Flushing. For some products that need to be flushed with nitrogen, they need to be flushed with nitrogen here to ensure the freshness of the products.
Filling I. It will fill the products into the pouches.
Filling II. If the quantity or grams is inaccurate, or if mixed products are required, secondary filling is required.
Top Seal I. Requires mounting interface.
Top Seal II. Seal the interface part.
Finished Products. Products are packaged.
Products are moved to other links.

11. What Are The Components Of Stand Up Pouch Machine?

The components in stand up pouch machine as follows:

Independent Film Unwind Unit

The film unwind unit can ensure good control of the film tensile force to make it more flexible for film roll width or pouch specification. After you set the parameter before starting this machine, it can offer you better stand-up pouch forming and making.

PLC Control System

The PLC control system can ensure intelligent machine control. You can set the parameters and make adjustments easily and fast.

Powder Filling System

The dual powder filling system is suitable for powder, and granules, and can help you with filling two products at the same which can greatly improve your efficiency and capacity.

Servo Advance System

The servo advance system can help you with a stable pouch advance with less deviation. It is easy to computerized specification change. With a big torque-moment of pouch advance, it is suitable for big-volume production.

Dual Filling Station

The dual filling station can fulfill two products simultaneously to reduce your time by half. It can also offer you high filling speed, high capacity, and high filling accuracy.

Light Walking Beam

The light walking beam can ensure you a faster working speed and longer operational life span.

Outlet

For receiving the finished products and transferring them into other parts.

12. What Are The Types Of Stand Up Pouch Machines?

Most of the stand-up pouch machines may only differ in appearance:

Horizontal Stand-Up Pouch Machine

The horizontal stand-up pouch machine started with a premade pouch and has a very flexible packaging application. It can apply to different types of product filling and packing, such as powder, liquids, granules, and solids. Different types of product filling and packaging may require different filling systems.

Generally, a servo auger filling system for powder filling, a piston pump filling system for liquid filling, a volumetric cup filling system for granule filling, and a multi-weightier filling system for solid filling.

Rotary Stand-Up Pouch Machine

Rotary Stand Up Pouch Machine -photo credits: bojupacking

The rotary stand-up pouch machine can automatically complete suction bags, date printing, bag opening, material filling, bag sealing, finished product output, and other links. And the horizontal stand-up pouch machine uses the way of horizontal filling and packaging, the rotary stand-up pouch machine uses the way of rotation. This can effectively use the space of the machine.

13. Stand Up Pouch Machine VS Sachet Machine

What Is Sachet Machine?

Sachet machine mainly completes sachet filling and packaging. Due to the limitation of sachet size and shape, the sachet machine is mainly used for filling powder, liquid, and pastes.

Sachet machines can automatically finish sachet forming, pouch making, dosing, and filling packing processes. It is the best packaging solution for small sachet fast packaging. With a flexible filling device, that can be applied for packing juice, yogurt, syrup, coffee powder, detergent powder, coffee beans, peanuts, etc.

Stand-Up Pouch Machine VS Sachet Machine

	Stand Up Pouch Machine	Sachet Machine
Machine Design
Bag Design
Bag Volume	High	Low
Bag Sealing	Tear notch, zipper sealing, zipper slides sealing, spout sealing.	Three-side sealing, four-side sealing, back sealing.
Working Principle	Stand up pouch forming, bag making, dosing and filling, sealing, etc.	Sachet forming, pouch making, dosing and filling, sealing, etc.
Purpose	Product packaging and display.	Dose dispensing.
Product Types	All kinds of liquids, pastes, powder, granules, and solids.	Only applied for liquids, pastes, powder, and small granules.
Machine Type	Horizontal type and rotary type.	Horizontal type, vertical type, and rotary type.
Automation	Fully automatic	Semi-automatic, fully automatic.

14. Is The Stand Up Pouch Machine Right For You?

The stand-up pouch machine is versatile and can provide you with customized solutions while protecting your products. With this perfect packaging solution, when you have a deep understanding, you will find that this machine will match your needs very well.

Customizable

The stand-up pouch machine can provide you with a variety of ways of customization, including stand-up pouch material (aluminum bag, kraft paper bag), stand-up pouch shape (small bag to heavy square bottom bag) and size, stand-up pouch sealing mouth way, the working speed and efficiency of the machine, etc.

Versatility

The stand-up pouch machine offers great versatility. Because it can be applied to almost all product packages. Including, food (fresh food, dried food and fruit, cereals, nuts, rice, spices, sauces, etc. ), soft & alcoholic drinks (wine, water, soda, sprites, etc.), hot drinks and beverages (coffee, tea, etc.), pet food and treats (cat food, dog food, fish food, etc.), garden supplies (seeds, pesticide, solid fertilizer), beauty & cosmetics (face masks, makeups, skin creams, etc.), health & fitness (protein powder, vitamins, supplements, etc.).

Recyclability

The stand-up pouches are all made of eco-friendly materials. In addition to being able to keep the contents of the bag fresh, it can also save materials and avoid the waste of packaging materials. Packaging materials are recyclable, in line with the concept of circular economy.

Conclusion:

The FAQ guide of stand-up pouch machines can not only share knowledge with you but also give you more inspiration. In addition to making good use of this packaging, the design of the entire machine is in line with the green development of the environment. If you have more questions or insights about this machine, you are welcome to consult our customer service or browse our website.

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Bottle Unscrambler Machine: The Complete Buying Guide in 2025

Bottle Unscrambler

Bottle Unscrambler Machine: The Complete Buying Guide in 2025

Have you ever wondered how industry production can deal with bottles thoroughly organized in a row? A bottle unscrambler machine is a perfect answer that helps every industry that deals with bottles for the filling process. This machine is capable of sorting disoriented bottles and making them ready for either filling or the washing machine. With advanced bio-engineering technology, you can swiftly do this job in a continuous fashion to boost your business productivity. If you’re planning to purchase this amazing machine, then we would suggest to please look into this guideline to know important points about the bottle unscrambler machine.

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1.What Is A Bottle Unscrambler Machine?

Bottle Unscrambler Machine

A bottle unscrambler machine is an important piece of equipment for larger production facilities that helps in sorting and arranging disorganized bottles into uniformly organized orientations and ensuring orderly alignment for the next integrated machine. A robust and durable machine that gives a reliable result in simple and easy steps. Simply, the machine’s functions are systemically performed by mechanical components (conveyor, rotary plate) as well as advanced sensory units such as PLC.

This machine is essential for various industries as it exactly senses the bottle and corrects them in the right direction. Whatever, the size, shape, or orientation of the object; it has the ability to detect them and increase capacity to maximize the production output and lowers the manual labor cost.

2.What Are The Industrial Uses Of Bottle Unscrambler Machine?

A bottle unscrambler machine is a significant piece of equipment that is specifically designed for handling bottles in bulk quantities. That’s why, it compasses a broad range of industrial applications. Some of them are discussed as:

Beverage Industry

A bottle unscrambler is a useful and ‘must-have’ machine in the production line of the packaging department. This machine can handle bottles of various shapes, sizes, and dimensions, for filling soda, drinks, mineral water, fruit juices, shakes, etc.,

Pharmaceutical Industry

Picture Credit- Sleeves bottle

A bottle unscrambler machine is an integral part of the pharmaceutical manufacturing industry for arranging and positioning bottles before they’re subjected to washing or filling machines for a uniform supply of disorder bottles. This machine is required for production sectors involved in pills, tablets, capsules, syrups, or powders packaging.

Cosmetic Industry

Products like beauty lotions, moisturizing creams, lip balms, lipsticks, sunblocks, concealers, mascara, and other cosmetics formulations always require a bottle unscrambler machine before the filling machine for receiving bottles in a sorted manner.

Food Industry

Picture Courtesy- SKS Bottles

You have seen many food products like kinds of ketchup, salad dressing, sweets toping, various oils, sauces, spices, and other products packed in bottles. This is quite understandable bottle unscrambler machine has unlimited benefits for boosting business in the food industry for fast productivity and handling large capacities in no time.

Chemical Industry

Picture Courtesy- FDA

Whether small or large bottles, the chemical industry deals with all of them for the packaging of alkalis, acids, organic and inorganic solvents, salts, and much more. A bottle unscrambler machine can sort bottles carefully and precisely no matter what material they’re made up of e.g. glass or plastic.

Nutraceutical Industry

Picture Courtesy: SKS Bottles

This industry deals with the manufacturing of health related products such as vitamins, protein, probiotics, energy drinks, etc., Therefore, a bottle unscrambler machine is a mandatory component of their production line for handline bottles in bulk and giving excellent output.

Household Product Industry

Picture Courtesy- Guardian

This particular category of industry is involved with the manufacturing of detergents, floor cleaners, toilet cleaners, room sprays, etc., A bottle unscrambler machine is of great value in this industrial section for a swift work process.

Automobile Industry

Picture Courtesy- NS Packaging

Products like engine oil, brake oil, grease, distill water for car engines, etc., are mostly available in bottles. The automobile industry cannot ignore this machine for its fast and efficient working in the production line of manufacturing products.

3.What Are The Benefits Of A Bottle Unscrambler Machine?

A bottle unscrambler machine is a simple and cost-effective way of obtaining unlimited benefits for industries. Some of the very important benefits are discussed below:

Dealing with Large Volumes of Disoriented Bottles

Picture Credit- ETSY

A bottles unscrambler machine is a super efficient equipment that begins your production with high speed per minute and gives a perfect result every second with no chances of errors or receiving any damaged bottle. This ultimately improves the entire productivity with reduces human error or time waste.

High Sensory Detectors with More Smoother Runtime

A Bottle Unscrambler Machine- Picture Credit HO MA

This simple machine is well-equipped with the advanced technology of intelligent sensory detectors that can immediately identify faulty bottles and prevent mingling or reject them to interfere with the production line; you can get more smoother processing with reduced downtime.

No More Worries About Labour Cost And Production Expenses

Bottle Unscrambler Machine- Picture Courtesy-CPHI

A bottle unscrambler machine has solved the problem of manual handling that’s not only time consuming but also causing more expensive in the term of labor costs. So, you can engage your skilled staff and other tasks and save production expenses.

High Compliance And Integration With Other Equipment

Bottle Unscrambler machine- Picture credit Zonesun

A bottle unscrambler machine is highly compliant with other equipment of the facility. This machine is suitable either standalone or can be integrated flexibly with a production line such as a filling machine, capping, etc., to increase the working speed of your production.

No Chance of Bottle Damage

A Bottle Unscrambler Machine- Picture Credit Ho Ma

As the machine can sense the bottle and sort them gently hence there is no chance of bottle damage, scratches, or breakage either lightweight or delicate items.

Touch Screen PLC Control System

Picture Credit- Plastic Machinery

A bottle unscrambler machine is featured with a touchscreen plz system that ensures easy operability by the user with just a single click. You can input the data prior to beginning with the process, the rest of the job will be automatically done by this robust equipment.

4.How Bottle Unscrambler Machine Works?

A bottle unscrambler machine follows quite simple working principle. The step by step description is given below.

Loading

The machine receives random position bottles. A dumped set of bottles are loaded into the hopper of the bottle unscrambler machine. Hopper itself is capable of accommodating thousands of bottles.

Elevation

The bottles are elevated randomly with an inclined conveyor fixed to pre-feeder bowl which is continuously rotating around fix axis. This rotation helps in sorting of bottles that drops into narrow canal one by one.

Orientation

By the action of vibratory or air jet blowers as well as rotation of pre-feeder rotary bowl, each bottle gets properly sorted to funnel or pockets to an up-right position. Machine is equipped with corrector that allows bottles in an upright position on running trail.

Discharging

The final sorted bottles are discharged out of the machine by the help of conveyor belt. They mostly transferred with or without pucks for stable and firm movement. Moreover, anti-back up conveyor sensor ensure smooth transport of bottles without worrying for jamming.

5.What Are The Major Parts Of The Bottle Unscrambler Machine?

PLC Touch Screen

This is the brain of bottle unscrambler machine that allows you to touch the screen to feed the working data such as speed, time, RPM, etc., Plus, this technology allows you when there’s anything alarming by notifying message or beep sound. In some cases, it immediately stops the machine and stores the data.

Anti Backup Conveyor

This is a transporting device that not only integrates the machine with next equipment but also supports the smooth movement of sorted bottles against jamming or overlap over one another due to anti-backup feature.

Frame and Structure Supporter

A bottle unscrambler machine is supported by a strong frame system which is made up of stainless steel. This network can hold the entire system with optimum distance from the floor of facility. The aim of machine frame to protect unwanted vibrations or shaky movement that can affect the process and accuracy.

Bottle Elevator

A bottle elevator is helps in elevations of random bottles gradually from hopper towards the rotational disc. This is part of the machine is particularly useful as it falls the bottles that organizes themselves with the helps of vibratory surface and force of unionize air effectively. This section is composed of slated plates that can easily hold bottles.

Sensors

This is an integral part of bottle unscrambler machine that detects the presence of bottles and identifies the orientation and position. This device notifies the system and making them real-time to adjust in order to maintain the accuracy as well as proper alignment of sorted bottles.

Bottle Pockets

The bouncing bottles are randomly fixes themselves into cavities which is known as bottle pockets or funnel. This section ensures that each bottle is hold into individual pocket so as they can move toward discharging unit such as conveyor. In some devices, this unit is features with narrow passage so bottles can fixes themselves effortlessly and moves out of the system.

Vibratory Disc

This is also known as vibratory feeder, circular turntable or bowl. This is a major part of the machine which vibrates and rotate to make disoriented bottles aligned and fed them into pockets for further transportation. The vibratory disc shaking is gentle that allow bottles to line up in a regular pattern and in a continuous flow.

Electric Cabinet

The machine functionality is basically controlled by electricals connection which is in-housed in a electric cabinet. The electrical components such as modulators, drivers, sensors, are important elements which are enclosed in this cabinet.

Hopper

A hopper or bottles loader is the somewhat a first section where random or disorganized bottles are fed in a bulk quantity. Hopper is a hollow tank that stores and facilitates a continuous supply of bottles to an elevator for sorting procedure.

Levelling Screws and Moveable Tyres

Machine itself is levelled from the floor in order to protect the system shaking and stabilize its structure. The leveling screw enable attaining an even position for the device whereas moveable tyres help in movement of machine from one place to other or to relocate the position.

6.How To Classify Bottle Unscrambler Machine?

A bottle unscrambler machine can be classified into various categories. For example:

BASED ON WORKING STRATEGIES

Conventional Bottle Unscrambler Machine

Conventional Bottle Unscrambler Machine

This is a simple and compact machine that uses mechanical properties to sort and organize bottles. Such as vibration, rotation, and air blowers to fix disorganized bottles.

Vision Based Bottle Unscrambler Machine

Vision Based Bottle Unscrambler Machine- Picture Credit- Directoryindustry

This is a new and sophisticated unscrambler device that works with help of computer-based technology involved photo-sensory detection to position random and disoriented bottles into a consistent form for production line. This machine is very modern in the term of working, design, and production capacity. This is all because of sensory cameras equipped within the system that process the image to identify the position of object.

Gravity Based Bottle Unscrambler Machine

Gravity Based Bottle Unscrambler Machine

A specialized device utilized in production facilities for arranging bottles via help of force of gravity. This is the prime reason behind its cost-effectiveness for any consumer who purchase this machine because it consumes lesser energy as bottles naturally fells downward due to force of gravity and align and organize in respective pockets for further production steps.

BASED ON MACHINE DESIGN

Waterfall Lifting Bottle Unscrambler Machine

Waterfall Lifting Bottle Unscrambler Machine

The machine is designed with an upright lifting system which looks like waterfall. This lifter helps in gently raising of bottle from down to high with adjustable chute which helps upward movement.

Linear Bottle Unscrambler Machine

Linear Bottle unscrambler machine – Picture Credit- KWT

A linear bottle unscrambler machine basically works in a continuous, straight, and a linear fashion. This machine treats unsorted bottles to arrange in a single row.

Centrifugal Bottle Unscrambler Machine

Centrifugal Bottle Unscrambler Machine

A centrifugal bottle unscrambler machine is a type of bottle unscrambler that is designed with a circular rotary disc which works on centrifugal force to arrange and align bottles.

BASED ON ALIGNMENT

Horizontal Bottle Unscrambler Machine

Horizontal Bottle Unscrambler machine Picture credit CVC

This machine beneficial and used in industries where production line where bottle arrangement take place in horizontal fashion. This machine is compact in structure but as compared to vertical it covers more space.

Vertical Bottle Unscrambler Machine

Vertical bottle unscrambler machine

A vertical bottle unscrambler machine is a specialized structure where bottle alignment takes place in a vertical fashion. This is mostly suitable for those production lines where bottles are required to be presented in stand up or vertically. This machine is most often used in those industries where space area is narrowed or limited because the equipment is designed with a smaller footprint.

BASED ON AUTOMATION

Semi-Automatic Bottle Unscrambler Machine

On the basis of automation, a semi-automatic bottle unscrambler machine has a manual feeding system of bottle placement and the rest of the process is done automatically. The bottles move directly within the system through a conveying system and have a better efficiency rate.

Automatic Bottle Unscrambler Machine

As the name describes, a completely automatic process is carried on in an automatic bottle unscrambler machine. Any type of bottle can be moved in an automatic bottle unscrambler machine and also the sorting process is done automatically.

BASED ON PREPARATION

Aseptic Bottle Unscrambler Machine

Aseptic Bottle Unscrambler Machine- Picture Credit CPHI

An aseptic bottle unscrambler machine is suitable for industries that deal with sensitive products, such as, biological units for medicines, blood samples, protein estimation samples, nasal sprays, ear solutions, injections, etc., The machine itself is an enclosed system that is designed following cGMP practices and following quality standards for strictly obeying all requirements of healthcare production. The machine can offer dust protection and it does not follow compressed air working, thus a centrifugal force or rotation is used for unscrambling bottles with the greatest care.

General Bottle Unscrambler Machine

High speed automatic bottle unscrambler machine Picture credit- SED

For solid dosage formulation or general usage of bottle packaging, a high speed automatic unscrambler machine is used for producing high production output. This is an open system that does not strictly follow an aseptic environment. This machine is used for production lines of tablets, capsules, household, nutraceutical, and food industries.

7.What Types Of Bottles Can The Bottle Unscrambler Machine Handle?

There are many types of bottles, jars, and containers that can be handled using a bottle unscrambler machine. Some of them are:

PET	PET (Polyethylene Terephthalate) is a light weighted plastic material that has a transparent layer and also can be recycled easily. PET bottles can easily be used in bottle unscrambler that further packs beverages and liquids.
Glass	Glass is a delicate material that is prone to break if handled improperly. A bottle unscrambler machine can gently deals with random glass bottles and sort them perfectly for the next machine. This material is commonly used in nutraceuticals, pharmaceuticals and the chemical industry in order to prevent product against physical factors like moisture, heat.
Aluminum	Aluminum bottles are also used in a bottle unscrambler machine due to their environmentally friendly nature and resistance to moisture. Aluminum bottles of different sizes move efficiently within a bottle unscrambler machine.
PP	PP or Polypropylene is also another type of plastic material that has high adhesive properties. PP bottles show high resistance against heat and are more precise than a PET material bottle. PP bottles that pass through a bottle unscrambler machine are mostly used for packing of hot and high temperature material.
PVC	Polyvinyl chloride bottles are the most commonly used plastic material around the globe. A PVC material has resistance against chemicals and is relatively light in weight as compared to others. PVC bottles of any size but low temperature resistant can pass within a bottle unscrambler machine easily.
HDPE and LDPE	High Density Polyethylene and Low Density Polyethylene bottles are used in places where bottles can be recycled and used in rough conditions. Both of the bottles are rigid in nature and used for packing of material liquid type material.

8.What Is A Complete Production Line Of Bottle Unscrambler Machine?

A bottle unscrambler machine offer excellent advantage of integrating with other machines of production process easily. This property has ranked bottle unscrambler as an essential equipment for every packaging industry. Following below is the relevant machines of production line.

1	Bottle Unscrambler Machine	Before entering any process, bottle must be fully oriented in an upright position with bottle unscrambler machine.
2	Counting Machine	A counting machine is integrated with unscrambler machine which senses and counts the product and fills into each bottle up to fed data.
3	Desiccant Inserter	Desiccant inserters are also an important machine as it ensures each bottle has placement of desiccator in order to protect development of moisture.
4	Capping Machine	A capping machine is also incorporated in the production line of a bottle unscrambler machine where specific caps are placed on the top of different types of bottles.
5	Sealing Machine	A sealing machine is used to make caps firmly tight and product as tamper evident. An electromagnetic induction of heat waves generates to seal the bottle tightly and ensure the product is freshen, leak-proof, and compliant.
6	Labelling Machine	A labelling machine is important piece of equipment used in production line for printing and sealing labels on the exterior of the bottles with mandatory information related to product, brand, production batch number, production date, and expiry date of the product, etc.,

9.What Are The Technical Problems And Solutions Of The Bottle Unscrambler Machine?

Some of the technical problems that occur in a bottle unscrambler machine with their solutions are:

No	Problem	Description	Solution	Image
1	Breaking Of Bottles	Once the system gets stopped at final attend and the sensors does not close the previous step. The bottles will overlap each other and can cause the breaking of bottles.	The problem can be rectified by the installation of highly precise and new detecting sensors so that the system may not get affected by it. Secondly, adjust the unscrambler disc.
2	Incomplete Unscrambling	When the initial moving mechanism gets overlapped and slow in rate, the system pushes bottles and causes incomplete unscrambler.	a. Align the gears and check the standards of shaft.
3	Jamming of Bottles	Bottles get jammed into conveyor and affect the transport.	Install anti-back up conveyor or reset the setting of the machine.
4	Bottles Passes in disoriented Manner	Sometimes inverted or disoriented bottles are accepted by the sensors.	Check speed of blowers, settings of vibratory disc, or re-install sensors.
5	Creation Of Noise/ Vibratory Sounds	In some of the bottle unscrambler machines, noise or vibration can be observed due to the improper tightening of equipment’s and parts.	a. Checking of machine parts as per plan and the timely greasing can cause a reduction in noise and vibration.
5	Unscrambler Disc doesn’t Move	This problem can be occurred to due failure in transmission or malfunctioning of friction plate.	Replace the friction plate and adjust the transmission gears.

10.How To Compare Different Types Of Bottle Unscrambler Machine?

The bottle unscrambler machine is a versatile invention in bio-sciences engineering that keeps on flourishing and bringing more and more advancement by the progression of new types. See the comparison chart below to know more about basic differences.

Property	Conventional	Rotary	Vibratory	Vision Based	Gravity
Operation	Works using rotation and sensors	Uses rotary disc to fix bottles in the pockets	Utilizes vibrations and gravity force to separate and bottle orientation	Use computer vision technology to sense the correct bottle.	Uses a gravity based mechanism.
Throughput	moderate	High-speed output, this is suitable for large industries	Lower production output as compared to rotary, and vision.	High speed working output	Moderate production rate.
Maintenance	Very simple	simple	Simple	Tricky and computer-based.	Relatively easier.
Structure	Moderate and compact required medium space	Moderate space	Moderate space	Require more space	Moderate space for installation
Bottle orientation	Accurate	Accurate	Accurate	Accurate and consistent	Accurate
Cost	Economical	Cost-friendly	Cost- friendly	Expensive as it is designed with high technology features	Cost-friendly

11.Why Maintaining a Bottle Unscrambler Machine Is Necessary?

To extend the machine's life and save production and maintenance cost; you must take care of the bottle unscrambler machine. This can allow you to meet the production throughput and low downtime. Some of the maintenance tips are discussed below:

Monitormachine workability routinely; monitor loose connections, reset the operating parameters, and store the data if needed.

Replace worn-out or damaged components once it indicates it malfunctioning by producing abnormal sounds or alarming notifications.

Timely lubricationis required to apply to avoid the progression of friction or jamming of movable parts. This activity can ensure faster and smoother operation.

Cleaningof the machine must be done properly by using air rinser, compressed air, and dried cloth to wipe off dust and dirt. This eventually minimizes the chances of cross-contamination and securing overall system.

12.What Are The Major Consideration Factors When Purchasing A Bottle Unscrambler Machine?

When investing on a bottle unscrambler machine it is significant to know the major objectives of your production so you can be possible enough to get the right one. Please find major points to keep in mind prior purchase.

Production Capacity

Picture credit JDA & BCM

Dealing with low to moderate production line possibly leads you to select whether conventional, gravity, or rotary machine. If you’re requiring a machine for a high production line, then computer based (vision) or automatic system will be worth buying; you must know the exact production capacity.

Major Features

Bottle unscrambler machine- Picture credit PHARMAPACK

Will the machine offer a fast changeover, what shapes of bottles can the machine run efficiently? What is bowl diameter? You must be well aware of these questions and features of the machine to get right equipment up to the mark.

Your Production Space

Picture Credit- SMFGMBH

Buying a bigger machine without measuring or estimating your production area would be the biggest mistake. Before selecting a machine, you know the area specification of the equipment as well as the installation flooring of your production facility. This decision must be made prior to selecting any device.

Good Manufacturing Companies & Reliable Supplier

Picture credit- KN Packaging

Keep scrutinizing good and reliable manufacturing and supplying companies is the foremost decision that won't compromise your selection. A good supplier can be found via an internet search, watching good reviews, and contacting them directly to assess their consultation and pre-customer services.

Conclusion

A bottle unscrambler machine is a valuable asset of successful production manufacturing sectors to obtain fast, accurate, and an upright-positioned objects for filling and packaging procedures. This machine gives ultimate productivity and excellent outcomes in a competitive sector. The story is not ended here, day by day advancements bring more and more improvisation in its structure and features that will definitely give you more throughput in the future. Are you still in doubt? Please contact our Team- We will gladly send you further information.

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Tablet Counter: The Complete Buying Guide In 2025

Tablet Counting Machine

Tablet Counter: The Complete Buying Guide In 2025

Are you an infant in the realm of pharmaceutical industry and looking forward for completing your production line by introducing an ultimate solution for precise counting? Or do you have a well established business of similar kind but your plan to thrive it is becoming a compelling factor to trace an advance equipment for enhancing efficiency and precision? If yes! You have finally found the answer which in form of tablet counter.

Tablet counter is a lucrative device known for the decisive role it plays in very sectors in form of counting tablets, pills and capsules. As the competition in market is gaining momentum for producing same things, industries are more concerned about using advance technology and revoking reliance on traditional methods. Therefore, if you are curious to explore in deep the tablet counter, this guide is providing you a good opportunity to acquire more knowledge of the machine's features, working mechanism, applications and more. Let's get started and fetch all you are looking for!

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1.What Is A Tablet Counter?

Tablet counter refers to the advance machine designed to effectively undertake the function of counting huge number of tablets, pills and capsules without any calibration. The machine is equipped with unique features of automatic tablet detection, intuitive operating interface and fast counting cycle which collectively contributes to its efficiency, precision and convenient handling.

This standalone device requires minimal or no interference of user during operation, and thus, carries out the assigned task by processing tablets from hopper through detection phase and ultimately tracking them to be loaded in bottles awaiting. At the same time, the machine aims at reducing tablet breakage, counting error and providing desired outcome. Therefore, every industry is keen to incorporate this effective tool into their manufacturing line to get targeted objectives.

2.How Does A Tablet Counter Functions?

Picture Courtesy: K D Machine

A standard tablet counter follows smooth and straightforward way for execution, however, there may be slight difference in the working principles of different types of tablet counter. Following points will clearly demonstrate the basic working steps followed by a tablet counter.

Setting-up Machine

Before starting operation, the operator must go for setting the basic parameters of machine on the basis of which machine will process tablets. It may include the amount of tablets to be counted and filled in each bottle.

Loading Phase

After setting parameters, the operator is required to feed the hopper with bulk of tablets. Once, the loading is done, machine is ready to start for further processing.

Detection Phase

Picture Courtesy: IDE

Moving forward, tablets will be gradually released from hopper onto the vibratory trays. These channels help in aligning tablets and removing defective tablets from the rest ones.

Counting Phase

Picture Courtesy: Cremer

The tablets will be moved from vibratory channels towards counting head where intellectualized system of sensors will count and pass the tablets to sleeve hopper.

Filling Phase

At last, with the help of filling nozzle, counted tablets will be released from sleeve hopper into the bottles laying over conveyor belt.

3.Which Benefits You Can Get By Using A Tablet Counter?

Tablet counter brings with it plethora of benefits which can change the fate of your business in the best possible manner. Let's have a look towards these attributes one by one:

Convenience of Handling

Undoubtedly, this machine brings greater degree of convenience due to its compact structure and simple processing features. Together, they contribute to easy handling of machine in terms of mobilization as well as execution.

Counting Precision

The foremost characteristic of tablet counter for which it has always been admired, is its excellence in counting the exact number of tablets and consequently, filling them into bottles. Similarly, it helps the manufacturers to bolster their aim of satisfying customers and avoid instances which can lead to grievances.

Hygienic Processing

Picture Courtney: iPharmachine

Tablet counter is made with GMP complaint corrosion resistant stainless steel and integrated with dust-proof system to fully assure that tablets are processed free of contamination.

Time-Saving

Indeed, tablet counter is the most suitable alternative to manual counting as it can fill up to 150 bottles in a minute. In this way, it saves the precious time which can be dedicated to increase production and also reduces humanly possible counting errors.

Clear Observation

The entire mechanism of tablet counting can be clearly seen via transparent window. It thus, enables user to keep an eye on the process of machine in order to keep it running smoothly.

Reliable

Tablet counter is reliable for being cost-effective and adaptable that it can be used for variety of tablets and pills irrespective of their nature, size and shape.

4.Can Tablet Counter Process Things Other Than Tablets?

A tablet counter is most compatible and resilient machine which not confined to the processing of particular kind of tablets, rather it has broad spectrum of application over numerous things including:

Tablets

Tablets

All types of coated, uncoated, sterile and compressed tablets are eligible to be counted by tablet counter.

Sweets

Sweets

Sweets such as chocolate balls, candies, chewable, jelly and bubble etc., can be counted while using this machine.

Capsules

Capsules of both categories including soft gels and hard gel capsules filled with powder, granules or essential oil are often processed by tablet counter.

Laundry pods

Laundry pods are water-soluble pouches filled with liquid detergent used for washing clothes. Among other things, these small pouches are also counted and filled by tablet counter into bottles.

Gel Blasters

Gel blasters are small jelly like balls filled with liquid gel which are used in toy guns for shooting. They are delivered in fixed quantity, hence, tablet counter is mostly found usable for counting and filling bulk gel blasters into different bottles and containers.

5.Describe The Key Components Of A Tablet Counter?

Tablet counter consists of several small to large components which together make a multidimensional ergonomic machine. These key parts are described below:

Hopper

Hopper is the feeding unit of machine where bulk of tablets or other stuff is loaded which are to be processed. It has a narrow opening at the end from where these tablets are gradually released via vibratory trough.

Detection Channel

Detection channel is a crucial component consists of vibratory trays. These trays are made up of stainless steel and constantly vibrate during process to serialize and detect tablets for counting.

Counting Head

It is the core part of tablet counter, where actual task of counting tablets takes places with the help of electric sensor.

Filling Nozzle

Filling nozzle is small tablet discharging hole attached with sleeve type hopper. It dispenses the counted tablets into bottles.

PLC Control System

It is the control system of machine with a touch screen display through which user delivers the commands to machine.

Conveyor

This key component of machine play vital role in the transportation of bottles from one place to another.

Stainless Steel Body

The entire body of machine is made up of 304 stainless steel, making the tablet counter more durable and stable during performance.

Electric Box

It is the control cabinet of machine with a web of servo drives and electromechanical components. It protects the internal machinery of tablet counter.

Rejection

Among other components, rejection system is one of the most crucial as it assures the bottles are accurately filled with desired amount of tablets, otherwise, it rejects them.

6.Explain The Various Types Of A Tablet Counter?

As a matter of fact, there are different levels of businesses which are directly or indirectly involved in manufacturing tablets such as large scale industries, medium scale production facilities or home based businesses. Therefore, keeping in view the divergent demand for tablet counter, it has been categorized into several types which can be better understood by looking in deep the below description:

Fully Automatic Tablet Counter

Fully automatic tablet counter is the most advanced and top quality machine made with cutting-edge technology to aid large scale industries. It is self-sufficient in its working once the desired parameters are fixed into it, the machine independently regulates tablet detection, dust suction, tablet counting and eventually filling them into bottles or containers. Its structure and cost are relatively larger than that of other types of machines, however, its fast performance help manufacturers in expanding their production and gaining more profit.

Semi-Automatic Tablet Counter

Semi-Automatic tablet counter another type of tablet counter which is more compact, precise and handy in nature. It follows simple procedure for working where the initial step such as feeding hopper and bottle require manual interference while the rest of counting and filling is carried out automatically. Since, it is low in its production in contrast to fully automatic machine, manufacturers who are running medium-sized food factories or pharmacies prefer using this type of machine.

Manual Tablet Counter

The most simplified form of tablet counter you will find is the manual one. It has extremely simple design comprising a mold tray, plain stainless steel base and a handle for easy holding. The user put tablets into molds and turns it after counting the tablets, where these tablets get collected at the end and thus discharged into container or bottle etc. Although, manual tablet counter is cheap and requires no techniques, it is a very slow process and only preferable to areas with low level of daily production such as home based businesses.

Digital Tablet Counter

Digital tablet counter is small size machine which do not use any hopper or vibratory trays for the counting of tablets and pills; rather it takes the help of sample plate to count tablets. It consists of sample plate, tight button, adjustable screw, speed controller, host and splash cover. It is suitable for variety of products including medicines, beans and sweet etc.

7.How Would You Distinguish A Fully Automatic Tablet Counter from Semi-Automatic Tablet Counter?

To better know the distinctions between fully automatic tablet counter and semi-automatic tablet counter consider the table below:

No	Factors	Fully Automatic Tablet Counter	Semi-Automatic Tablet Counter
1	Nature	Fully automatic and self reliant	Depends upon manual handling
2	Structure	Complex with multiple components	Simple with precise construction
3	Productivity	High productivity by filling up 150 bottles per minute	Relatively low productivity by filling 10-30 bottles per minute
4	Cost	Expensive due to automation	Cost-effective with low level of automation
5	Application	Large scale industries	Moderate or small factories
6	Example

8.In Which Areas A Tablet Counter Can Be Brought Into Use?

Table counter serves as a primary tool for counting in range of areas which are highlighted below:

Pharmaceutical Industry

It is one of the largest industries which discovers and produces millions of tablets, pills and capsules every day. Counting such gigantic volume is humanly impossible, therefore, a tablet counter has been introduced to resolve this issue.

Nutraceutical Industry

Unlike pharmaceutical industry, nutraceutical industry aims at strengthening the natural immunity of humans to cure diseases. These medicines are obtained from sources such as fruits, vegetables and herbs etc. Hence, the growing demand for supplements has made the industry dependent on using tablet counter.

Veterinary Industry

Veterinary industry encompasses the dental, medical and surgical treatment of animals where most of the time help of medicines are taken. In this way, the presence of tablet counter has also been found there.

Cosmetic Industry

Nowadays, the focus of cosmetic industry is shifted towards providing natural solutions, for strengthening hairs, reducing dark circles and aging skin, in form of gummies and capsules containing vitamins, proteins and essential oil. Therefore, processing of these ingredients require the assistance of tablet counter.

Food Industry

As there is no age restriction to enjoy the colorful flavors of sweet and juicy gummies, candies and chocolates. Similarly, there is no way out for manufacturers to make these goods process for you with machine other than tablet counter.

Chemical Industry

Like other industries, chemical industry has also been influenced by the efficient performance of tablet counter in a way that most of the chlorine tablets, laundry pods and confidor tablets are processed by this machine.

9.How To MaintainA Tablet Counter?

It is worthy to mention here that a tablet counter needs regular maintenance and cleaning to keep it on right track. Therefore, to familiarize you with the maintenance of tablet counter, explanation is given below:

Machine Setting: Accurate machine setting is the core step for successful operation. Therefore, you need to set the parameters of machine in accordance with your desired requirements. In addition, checking the machine setting each time before starting an operation can reduce the chances of possible errors.

Cleaning: It is necessary to clean your tablet counter on daily basis in order to remove the debris and tablets residues. The cleaning procedure of machine is quite easy. You can use potable water to wash the different parts of machine like hopper, vibratory trays and sleeve hopper etc. For parts like control panel and conveyor belt, you can use isopropyl alcohol sprayed cloth for dirt wiping.

Lubrication: A tablet counter uses several components at the same time to carry out the counting task such as conveyor belt, counting channels, and tablets outlet. These parts are driven by internal mechanical system which needs proper lubrication to run smoothly. Therefore, lubrication is inevitable for successful operation.

Examining External structure: Another aspect of tablet counter maintenance requires you to examine the external structure of machine before and during operation. It will help you in timely correction of these parts. For instance, if any screw is loose or missing and the wire is worn out you may be able to go for troubleshooting.

10.What Are The Auxiliary Devices For A Tablet Counter?

A tablet counter may be integrated with other machines to make a full-fledged production line and bring ease in whole processing. These auxiliary devices are mentioned below:

Turntable

Turntable is a machine with rotary table and supporting stand. It is used for serializing bottles before they go to filling machine.

Desiccant Dispenser

As the name justifies, desiccant dispenser is a machine used in the production line of tablet packaging. This machine dispenses desiccant pouches, containing silica gel into tablets filled bottles which helps in reducing the risk of condensation.

Cotton Dispenser

This machine is employed to cover the neck of tablet filled bottles by releasing hard cotton over it.

Capping Machine

Capping machine is designed to cap the filled bottles with neck. The necks of bottles are loaded in hopper of the machine from which it is delivered one by one and screwed over the bottles.

Induction Sealing Device

It is an electromagnetic device which uses heat radiation to get the hard cotton or aluminum foil stick to the neck of the bottle for protecting against moisture, temperature and harmful ultraviolet light.

Labeling Machine

Labeling machine plays a major role in tablets packaging. It is used to label the bottles with adhesive stickers or paper labels containing useful information about product usage, expiry date and prescription etc.

Cartoning Machine

Cartoning machine is the ultimate equipment which finally pack the processed tablet bottles into separate cartons.

11.How To Diagnose The Common Pitfalls Of A Tablet Counter?

To counter the possible problems caused when operating a tablet counter, the table below is containing useful description:

No	Pitfalls	Causes	Diagnosis	Picture
1	Erroneous Counting	It happens when the counting time is fixed incorrectly	Accurately set the tablet counting time by using HMI
2	Abrupt alarm without malfunction	The sensors may be overloaded by tablets' residues	Clear the sensors with cloth and empty dust collection box
3	Loud noise during process	Either screws are loose or vibratory trays are not well linked to outlet	Tight the screws and align the trays in accordance with outlet
3	Tablets dispersion or leakage	The distance between nozzle and bottle is wide	Decrease the distance by adjusting nozzle

12.What Are The Quality Standards For A Tablet Counter?

Tablet counter is a machine designed to fulfill the responsible task of processing tablets, pills and capsules which requires highly hygienic and safe environment. Therefore, it becomes inevitable to check whether the machine you are going to purchase is complying standard quality certifications? For this below information can be useful:

GMP

GMP

Good Manufacturing Practice or current manufacturing good practices is an international aspect of quality standards which has established principles regarding safety of all those equipment which are to be used for pharmaceutical and biotechnology manufacturing purposes.

ISO

ISO

International Organization for Standardization is an independent organization formed for the purpose of generating such quality standards whose compliance will produce safe and quality products.

FDA

FDA

Food and Drug Administration is an American regulatory agency established to ensure safety of the processing and manufacturing of drugs and associated products such as medicines, vaccines and medical devices.

CE Standards

CE standards are formulated for the purpose of promoting manufacturing and supplying of safe goods and products for countries wishing to trade in European Union countries.

The above discussed standards provide an opportunity for you to check the quality of machine you are going to purchase. If your tablet machine is complying the above standards, it is safe to use.

13.How To Choose An Excellent Tablet Counter For Your Business?

Sometimes, choosing the right tablet counter for your business becomes tricky. To help you solve this issue, we have provided few points for your ease:

Capacity

One of the essential factors to consider is the machine's capacity for potential production. It is because you are going to purchase the machine in order to fulfill your production requirements. Therefore, the capacity of tablet counter complement your need than it is the suitable one

Customization

Another aspect to look for is the degree of customization machine possess. For instance, there must be enough room available for customization in case you have diverse products to process.

Budget

Considering your budget is a significant factor to look for. It will help you choose the best possible tablet counter within your range.

Customer Service

Last but not the least; make sure to check the customer support on part of your supplier. It can be really helpful for you in future, whenever, you face difficulty in machine setting or feel need for change of parts.

14.What Is The Aipak Collection Of Tablet Counter And How It Differs From Other Machines Available In Market?

Aipak has a huge collection of tablet counter which can suit your small to extra large industrial production. Below details will better display you the versatility of machine Aipak is offering:

Machine	Automation	Speed/ Bottles per min	Filling Nozzle	Application
Desktop electronic tablet counting machine	Semi-Automatic	10-30 BPM	Single	Medium Scale
APC-8 Automatic Tablet Counting Machine	Fully Automatic	10-30 BPM	Single	Medium Scale
APC-24 Automatic Counting Production Line/capsule /tablet counting machine	Fully Automatic	20-80 BPM	Double	Large Scale
APC-48 Brand New Simple Operation Tablet Counting Machine	Fully Automatic	40-150 BPM	Four	Extra Large Scale
APC-202 automatic tablet counting machine	Fully Automatic	20-40 BPM	Double	Large Scale

Aipak Pharmaceutical Equipment is a proficient company specialized in manufacturing all kinds of pharmaceutical equipment from processing till last step of packaging. The company offers extensive range of tablet counter with immeasurable incentives. Some of them are highlighted below:

Quality Certified

All of their equipment are certified by all the international quality standards including CE, FDA, GMP and ISO. It affirms that all of their equipment are no exception to quality.

Warranty

The company's unique policy of 12 months warranty distinguishes it from all other companies who are not willing to give any type of assurance.

Huge Variety

While going through Aipak collection of tablet counter, you will find huge varieties of machines with diverse features and applications making them resilient to process products beyond tablets and pills.

Full Installation and Training Support

The company is providing full Installation and training support to the customers followed by 24/7 sales and technical support.

Conclusion

In a nutshell, tablet counter is the most desirable device for every manufacturer who is engaged in pharmaceutical, food, cosmetic and other relevant industries. Its efficiency, precision and safety are the qualities every business wants to be well known for. Hence, its significance cannot be overlooked. If you also want to get benefits from this magnificent machine Aipak Pharma is complying all the needs. So, don't make any delay and approach us via given link!

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CONTACT US

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WhatsApp Us: +86 181 7101 8586

The Buyer's Guide

Want to get Best Price Tablet Counter from China?

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Plastic Bottle Washing Machine: The Complete Buying Guide in 2025

Bottle Unscrambler

Plastic Bottle Washing Machine: The Complete Buying Guide in 2025

Did you know your product is at High Risk of Contamination if not cleaned Properly? We know the solution! A plastic bottle washing machine is a perfect answer for general and sterile preparations. You can defy its importance as it ensures the filling container is free from foreign particles.

Before purchasing a plastic bottle washing machine, we would suggest reading this guideline. Here, our experts have collectively answered the major questions that everyone looks for. Have a look!

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1.What Is Plastic Bottle Washing Machine?

Plastic Bottle Washing Machine- Picture courtesy alibaba

A plastic bottle washing machine is a mechanical equipment that cleans and sanitizes the bottles by the action of various washing stages including pre-washing, rinsing, deep washing, and air-drying (optional) to offer contamination-free packaging material.

The machine has the ability to wipe not only the inner surface of the object but the exterior as well.

The washing action takes place by high nozzle sprays, water circulation systems, air filter blowers, and sensors. Plastic bottle washing machine is available in various types and sizes so it can be compliant with large and small production lines. The entire motive behind its development is to wipe off the presence and adherence of every minute particle that may progress an unwanted cause of contamination and affect the quality of your brand.

2.What are the Major Industrial Applications of Plastic Bottle Washing Machine?

When it comes to the uses of a plastic bottle washing machine; nevertheless you can find this robust machine everywhere in industrial manufacturing units. Some of the important applications are discussed below:

Chemical Industry

Picture Courtesy- Amazon

The chemical solution is always reactive in nature. One must keep in mind to use cleared and wiped plastic bottles prior to filling them. A plastic bottle washing machine is an essential tool used in this sector for cleanup bottles used to store products like alkali solvents, acidic solutions, buffers, salts, and organic and inorganic products.

Nutraceutical Industry

Picture Courtesy: SKS Bottles

Nutraceutical products include protein powders, probiotics, multivitamins, energy powders, supplements, etc. are available in solid, powders, or liquid form that must be stored in sanitized plastic bottles after being washed and dried by a plastic bottle washing machine.

Pharmaceutical Industry

Picture Courtesy- Tip Top Prop

A plastic bottle washing machine is used in this sector to clean plastic and glass bottles required for the filling and packaging of tablets, capsules, syrups, ointments, sterile preparations, and topical preparations like balms.

Food Industry

Picture Courtesy- Made in China

The filling of food products such as sauces, powders, kinds of ketchup, purees, dressing, topping, and spices, etc needs cleaned bottles which are achieved by using a plastic bottle washing machine.

Cosmetic Industry

Picture Courtesy- Primepac

Cosmetic formulations such as creams, lotions, face foundations, eye conclears, and other products are filled with high-grade sterile plastic bottles that must be passed from the plastic bottle washing machine.

Beverage Industry

Picture Courtesy- Medical News Today

Cleaning and washing plastic bottles prior to packaging and filling soda, juices, mineral water, and energy drinks must require this machine in the beverage industry.

Research and Development

Picture Courtesy CPLAB

This field of science is always looking for perfection. A plastic bottle washing machine is worth buying tool used in the research and development sector for storing sterile samples such as blood samples, plant extracts, biological samples, etc.,

Household Industry

Picture Courtesy Waster.com

Detergents, floor cleaners, floor disinfectants, powders, and shiners, are commonly used filling products used in this industry that are always treated with a plastic bottle washing machine.

Pesticide Industry

Picture Courtesy-Indiamart

Pesticidal filling products must be cleaned and washed as they’re prone to react with foreign particles and affect the potency. A plastic bottle washing machine is a must-have equipment in the pesticide industry production line.

3.What are Advantages of Plastic Bottle Washing Machine?

Plastic bottles washing machine has several advantages and checks all the boxes of hygiene, cleanliness and efficiency. Some common advantages that a plastic bottle washing machine offers are as follows.

Hygiene and cleanliness

Picture Courtesy- NPACK machine

Plastic bottle washing machine provides high level of hygiene and cleanliness by utilizing its multiple nozzles, directing water and soap at all possible angles ensuring a thorough wash in every cycle.

Labor saving and time effectiveness

All automatic plastic bottle washing machines usually require one operator to input machine parameters and perform the entire operations and as many as thousands of bottles can be washed in a given period. Thus cutting labor cost and providing clean bottles in just minutes.

Water saving

Picture Courtesy- Alibaba

Plastic bottle washing machines are designed in such a way that they utilize minimum water for each cycle i.e. water nozzles direct high pressure jets in preset quantities to wash every inch of bottles and save gallons of water which otherwise would have been wasted while cleaning.

Offering High Production Capacity

The quality of wash remains consistent for thousands of working hours provided that machine is looked after and maintained as recommended by manufacturer.

A trustworthy Choice

These machines are utilized in highly regulated industries such as food and pharmaceuticals therefore, these machines are designed to meet both local and international stringent regulatory requirements.

All rounder

Not only plastic bottle washing machine can wash bottles of different sizes or shapes, some models can be used to wash recyclable bottles. These special machines are provided with label removing unit that removes labels using water jets.

4.What is Step-by-Step Working of a Plastic Bottle Washing Machine?

The working principle of a plastic bottle washing machine is super easy. For your understanding, we’ve described them step by step.

STEP NO. 1: LOADING

The washing process began with the loading of upright and properly oriented bottles received from the conveyor belt which is usually connected to the bottle unscrambler. Here, presence of tipping cradle ensuring that bottles are loaded inverted toward the receptacles. This is an important mechanism that is offered with a safety switch which stops if any bottle is jammed between tipping cradle and conveyor so breakage of bottles can be avoided. The received set of plastic bottles is transferred toward the washing zone.

STEP NO. 2: WASHING

WASHING

The washing step is the major stage where several washing sessions are taken place such as:

Picture Courtesy-Traktech

Pre-Soaking

With the help of conveyor chain plastic bottles are first introduced toward pre-soaking zone where warm water around 35ºC helps in removing of foreign particles., This step is essential before the final wash where plastic bottles are subjected to general wash in order to loosen the sticky residues on the inner and outer surface of the plastic bottle.

Washing

Next washing of bottle using jetting system of hot water around 55ºC is jetted inside and outside surface of bottles to remove if any particle left over surface. A high pressure nozzle sprays explode water on the plastic bottle with high intensity. This ensures plastic bottles are washed and cleaned with unwanted particles.

Detergent Soaking

Next conveyor chain brings plastic bottle in detergent soaking zone where hot detergent solution around 75ºC helps in the dissolving greasy, fat particles and flushed out the solution.

Rinsing

In this section rinsing of plastic bottles is involved with water jet system around 65ºC hot water. In order to assure that plastic bottles are cleaned; final rinsing can be done by spraying either water for injection which will eliminate the chances of any remaining or leftover particles inside or outside the plastic bottles. For cooling, water jet around 15ºC is passed through bottles to assure suitable temperature.

STEP NO 3: Air Drying

Picture courtesy- Solvair

Machines are designed with high air-jet heated blowers that simultaneously blow air with high temperatures (75ºC) that can dry the plastic material rapidly and then discharge through the system via a conveyor.

5.What are the Primary Parts of Plastic Bottle Washing Machine?

Parts of machine may vary from manufacturer to model to degree of automation that is why it is always advisable to consult manual provided with your machine. However, basic components of plastic bottle washing machine remain same and include following components.

Parts	Description
Loading Unit	Depending on model a plastic bottle washing machine may be equipped with either infeed conveyer or both infeed as well as outfeed conveyer. The bottles for washing are loaded onto infeed conveyer and after the washing process the bottles are collected from outfeed conveyer. Operated by PLC control the conveyer system comprises of pulleys, conveyer belt etc.
Pre-wash unit	Many automatic and large plastic bottle washing machines contain a pre-wash unit where plastic bottles are washed before entering the main washing cycle. This pre-wash unit removes major chunks of debris and impurities and allow partially cleaned bottles to enter the washing cycle for a proper wash.
Sensor	The main function of bottle sorter is to remove damaged bottles from the main line allowing only the specified bottles to enter the washing cycle. Bottle sorter can be for different types and shapes of bottles.
Main washing unit	The main washing unit hold different multiple nozzles that spray water jet or soap thoroughly cleaning bottles from every angle, nook and corner. The machine first spray soap followed by multiple high pressure water jets for proper cleaning. The high pressure jet remove stubborn stains and dirt that might have escaped the pre-wash unit.
Steaming unit	In order to remove any chances of microbial contamination some machines have steaming unit where bottles are subjected to low temperature sterilization. Some models utilize hot water unit instead of a steaming unit for sterilization.
Drying unit	After washing the next phase in washing cycle is drying of bottles. This is carried out by using pressurized air jets for few minutes to remove water droplets. Alternatively, a low temperature heating unit can also be used that completely dries the bottles.
Control panel	Most machine these days have a digital control panel a part of human machine interface (HMI) which allows for entering required process parameters including machine speed, number of bottles, types of bottles, temperature of heating unit etc. Additionally, the control panel can also be used to switch on and off machine and abrupt halt of process in case of an emergency.
Stainless steel body	In order to limit contamination and reduce microbial growth main body of plastic bottle washing machine is made up of industrial grade steel as per regulatory guidelines. Steel not only reduces contamination, allows easy cleaning but also is sturdy and adds to working life of the machine.

6.What is the Basic Classification of Plastic Bottle Washing Machine?

Today, a plastic bottle washing machine is offering various types of models and types for their consumers. The basic classification of plastic bottle machine is given below:

Manual hh

ACCORDING TO MACHINE AUTOMATION

Manual Plastic Bottle Washing Machine

Manual Plastic Bottle Washing Machine- Picture Courtesy Indiamart

A low cost machine suitable for small batches where bottles are fixed on washing molds present in the machine and water rinsing began upon opening the water valve. This is a simple machine commonly used in education sectors, protype developmental sector or production with astringent budget.

Semi Automatic Plastic Bottle Machine

Semi Automatic Plastic Bottle Machine- Picture Courtesy- Indiamart

This is good solution for running moderate to large production batches that require manual handling for loading and unloading the plastic bottles. The remaining task is performed by the machine itself. This machine offers rapid changeover so suitable for various shapes and size of bottles. Like, manual machine; it is also an affordable equipment involved with cleaning of large capacity output such as washing hundreds of plastic bottles in one hour.

Automatic Plastic Bottle Washing Machine

Automatic Plastic Bottle Washing Machine- Picture Courtesy Alibaba

This is fully automatic device requires no manual intervention. Loading of bottles can be achieved by conveyor that receives sorted bottles from unscrambler machine. A sophisticated step by step procedure is followed by automatic system fed by an operator using PLC system. This machine is super giant in the term of working as it can wash and dry hundreds of bottles in minutes and thousands of bottles in each hour.

ACCORDING TO MACHINE SIZE

Benchtop Plastic Bottle Washing Machine

Benchtop Plastic Bottle Washing Machine- Picture Courtesy Bottle washer

A small solution for those sectors that require super hygienic material for their practicals or production procedure with a limited space, limited budget, or small batches. A benchtop plastic bottle washing machine is available in semi-automatic feature that can manage moderate bottles washing in each session.

A Large Plastic Bottle Washing Machine

Large Plastic Bottle Washing Machine- Picture Credit Qpack

This is an ideal machine for big industries where day and night production processes are carried out automatically. The entire setup offers rapid change over time and flexibly can be integrated with other machines of the production. This machine requires a large installation space and gives you higher washing capacity with 100% robustness and accuracy each minute.

ACCORDING TO MACHINE STRUCTURE

Tunnel Plastic Bottle Washing Machine

Tunnel Plastic Bottle Washing Machine- Picture Courtesy Indiamart

A large industrial plastic bottle washing machine where machine design resembles tunnel like structure which is used to treat bulk quantities of unwashed bottles and discharge cleaned bottles after passing through various transition of stages. For example, pre-washing, washing, rinsing, etc., Machine can wash various size, shapes, and different material bottles rapidly and delicately.

Linear Plastic Bottle Washing Machine

Linear Plastic Bottle Washing Machine-Picture Courtesy Watersman Engineering

These machines are designed with simple linear structure with conveyor unit that is responsible for transporting plastic bottles into pre-washing, washing, and other zone of the machine in a linear fashion. This machine is suitable for medium to large production batches.

Rotary Plastic Bottle Washing Machine

Rotary Plastic Bottle Washing Machine-Picture Courtesy Alibaba

As it names show, a circular carousal or turntable is responsible for subjecting bottles for various stages/units of the machine for efficient washing procedure. As compared to linear this machine can encompass with large batches.

ACCORDING TO DIFFERENT WORKING PRINCPLE

Air Jet Plastic Bottle Washing Machine

Air Jet Plastic Bottle Washing Machine- Picture Courtesy- Indiamart

This system basically utilizes a powerful pressurizes water nozzles to spray water and compressed air to eliminate dirt and sticky particles adhere on inner and outer walls of the bottle.

Ultra-Sonic Plastic Bottle Washing Machine

Ultra-Sonic Plastic Bottle Washing Machine- Picture Courtesy- SPM

This is also known as a sonicator that works upon generation of high vibratory waves in the form of striking bubbles that gently implodes over walls of the bottles to wipe the unwanted particles. This is suitable for highly sensitive laboratories or healthcare industries.

7.What is the Complete Production Line of Plastic Bottle Washing Machine?

The following picture above demonstrates auxiliary equipment used in a production line of plastic bottle washing machine. The function of this complete unit is discussed below:

Machine	Functions	Picture
Bottle Unscrambler	Before subjecting plastic bottles to washing machine it must be oriented in aligned and uniform pattern. Moreover, detection of damaged bottles also must be done. For this a bottle unscrambler machine is integrated with plastic bottle washing machine to receive bottles perfectly undamaged and in upright position.
Plastic Bottle Washing Machine	Upon receiving plastic bottles, they passes through the machine and cleaned bottles are discharged toward filling machine.
Tablet/Capsule Counting Machine	A cleaned set of plastic bottles are subjected for counting procedure using this machine. At this stage, one must assure that filling material is contamination free and product storage with no moisture content.
Capping Machine	Once plastic bottles are filled, they’re subjected to capping machine to secure insight product against leakage, spillage, and interacting with external environment. Machine has ability to twist caps around the next of bottles and discharge them for next machine of the facility.
Labelling Machine	This integrated machine offer significant job by printing and applies label over neat and cleaned external surface of the bottle. One must keep in mind, if external surface is uneven, labelling won’t be done properly. The labeling machine can stick label with mentioned information about the ingredients, date of manufacturing, expiry, dosage, batch number etc.,
Cartoning Machine	A ready to market filled product is always subjected to cartoning machine for safe transportation. A cartoning machine can flip the carton and insert the bottle with leaflet automatically.

8.What Other Things Plastic Bottle Washing Machine Can Wash?

Beside plastic bottles, a plastic bottle washing machine can wash several other things. For example,

Type	Description	Picture
Ampoules	These are commonly used in medical, nutraceutical, cosmetics, and pharmaceutical section. Plastic bottle washing is of great benefits as it features ampoule washing as well.
Vials	Different sizes vials can be washed using plastic bottle washing machine which is required for sterile preparations such as antibiotics, vaccines, chemotherapeutic agents, optic solutions, and so on.
Beakers	Glassware and laboratory objects such as tubes, beakers, funnels can be washed using plastic bottle washing machine.
Cans	Cans of various sizes are commonly used for storing beverage, food products are washed with this machine.
Jars	Plastic bottle washing machine can be adapted for cleaning various jars used in broad applications.

9.What are the Technical Challenges and Solutions of Plastic Bottle Washing Machine?

Technical Problem	Possible Causes	Solution
Plastic Bottle Jamming	This mostly happens when bottle stuck between tipping cradle and conveyor	Reset machine setting. Replace safety switch. Check and clear the passage between tipping cradle and conveyor.
Improper Bottle Cleaning	This happens due to low jet pressure of water. Clogging of pressure nozzles.	Set the parameters to achieve required water jet pressure. Check water temperature and unclog the nozzle sprays
Plastic bottle damage	This can be caused by excessive pressure during. The misalignment of grippers can also damage bottles by scratching the surface.	Adjust the speed of conveyor. Validate the positioning of bottle and readjust the alignment.
Bad Smell from Plastic Bottle Washing Machine	This can be due to low maintenance and improper cleaning.	This is recommended to clean and maintain machine on the regular basis to avoid development of mushy smell.

Conclusion

A plastic bottle washing machine is an ideal addition in the packaging line that ensures your products safety and security by clearing unwanted materials inside and outside the bottle. Of course, this robust machine is significantly important to gain customer’s satisfaction and maintain competitive reputation in the marketplace. Before, purchasing the machine, we would suggest to please contact our team for more information and machinery details. Send us short message now!

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Freezer Paper VS Vacuum Seal

Vacuum Sealer

Freezer Paper VS Vacuum Seal

There are many methods can be used to store food in your fridge, for the purpose to extend its shelf life and prevent it from spoilage, and there are the most effective two, which are freezer paper and vacuum seal. Both the two storage methods have their own advantages and disadvantages, and they are suitable for different storage demands.

Therefore, in this blog, you will see the comprehensive comparison of freezer paper seal and vacuum seal so that you can figure out which one of the two methods is right for you. You can compare freezer paper seal and vacuum seal in different dimensions, such as pros and cons, storage principles, applicable food products and so on. Now let’s begin exploring!

Add a header to begin generating the table of contents

1.What is freezer paper seal vs vacuum seal?

Freezer Paper Seal

Freezer paper seal is a kind of food preservation method which is to use freezer paper to wrap food products for the purpose of freezing, this paper has a layer of plastic coating on one side, can protect the surface of the food product, prevent it from the air and avoid freezer burn and moisture loss. Freezer paper seal is often used to store meat, seafood, baking products and others.

Vacuum Seal

Vacuum seal is an effective food preservation method, the food product is packed in vacuum seal bag, and the air inside the bag is extracted by a vacuum sealer, and then it is sealed tightly. Vacuum seal can not only be used to storage food products, it can also pack medicines, chemicals, hardware, electronic components and so on.

2.What are the pros and cons of freezer paper seal vs vacuum seal?

As common storage methods, both freezer paper seal and vacuum seal have their own pros and cons, these points can help you judge which method is more proper to you. Keep on reading to learn the pros and cons of freezer paper seal and vacuum seal.

(1). Pros and Cons of Freezer Paper Seal

Pros:

Relatively speaking, freezer paper seal is more cheap than vacuum seal, freezer paper is easy to purchase, which is very convenient.
Freezer paper seal is very simple to operate, you just need to use the plastic coated side of freezer paper to wrap food products.
Freezer paper is very durable, it can provide better protection to food products, if you store food by using freezer paper seal and then put it into fridge, it can be stored longer.
Freezer paper seal is beneficial for separating frozen food products and prevent odor.

Cons:

Cons of Freezer Paper Seal-Photo Credit: Oliver + S

A piece of freezer paper can only be used to wrap a piece of food, if you need to pack many food products, you need to consume more freezer paper and time.
Different from vacuum seal, the application of freezer paper seal is limited, it can only be used to store food.
When stored in the fridge, the food product which is wrapped by freezer paper can not last as long as food that are vacuum sealed.

(2). Pros and Cons of Vacuum Seal

Pros:

By using vacuum seal, you can storage food products for a long term.
Using vacuum seal to store food, you can seal a lot of food for one time, which is very convenient.
As is mentioned that vacuum seal is a versatile storage method which is not only used for food preservation, it can also be used to store other objects.
Vacuum seal not only extends the shelf life of food, but also maintains the original color and taste of it.

Cons:

To adopt vacuum seal to store food, you need to purchase a vacuum sealer first, which costs more than freezer paper seal.
Not all food products are suitable for vacuum sealing, you can not use vacuum seal to store raw onions, fresh mushrooms or fresh garlic.
Not all plastic bags are suitable for vacuum sealing, you need to separately purchase special vacuum seal bags to store your food.

3.What are the applications of freezer paper seal vs vacuum seal?

Both freezer paper seal and vacuum seal can be used for different applications, wanna to know in which field can they play their functions? Just read the following content carefully.

Application of Freezer Paper Seal

Food Industry

Food Industry-Photo Credit: Delta Paper

The most common application of freezer paper seal is in the food industry, it is used to wrap fresh and frozen meat, fish, fried food, hamburger, sandwich and many other food products, to keep them from coming into contact with the air, therefore, these products can be stored longer.

Application of Vacuum Seal

Food Industry

When talking about the application of vacuum seal, it is no doubt that the first one which you think about is the food industry. You can use this method to store a large amount of foods, which including meat, fruit, vegetable, bakery products, nuts, dairy products, snacks, seafood and so on. Vacuum seal can prolong the shelf life of these food products in the largest degree.

Medical Industry

Another common application of vacuum seal is in the medical industry, the raw materials of drugs, herbs, all kinds of capsules and tablets, medical tools and so on, these objects all can be stored by vacuums seal, to maintain their hygiene and stability.

Agriculture Industry

To be honest, crops also need to be well preserved, thus vacuum seal is also applied in agriculture industry, to extend the storage time of vegetables’seeds, rice, wheat, whole grains, buckwheat, etc. By adopting vacuum seal, the agriculture products can be kept in high quality, which boost the development of the whole industry.

Metal Industry

As you know, there are some metal such as magnesium metal, pig iron, carbon cable steel, copper alloy, aluminum alloy, coating and so on, are easy to rust. So is there any way to solve this problem? That is vacuum seal. Using vacuum seal, the metal products are packed tightly and won’t be exposed to the air, which prevents them to rust and oxidation.

4.How do freezer paper seal vs vacuum seal work?

Do you know why can freezer paper seal and vacuum seal prolong the storage time of food items? How do they work? Here you can unravel your doubts.

Principle of Freezer Paper Seal

Principle of Freezer Paper Seal-Photo Credit: Instructables

As you can see, freezer paper seal is to use a type of thick freezer paper which has a plastic coated side. When you use this side to wrap food, for example, meat, the freezer paper can keep air away the meat and lock the moisture of it. Therefore, freezer paper seal can keep food fresh and extend its shelf life.

Principle of Vacuum Seal

Vacuum seal is to extract all the air inside the vacuum seal bag which packs food, let it under a vacuum condition. In this state, there is no air, and naturally there is no oxygen contained in the air, under low oxygen condition, germs and microorganisms have no living environment and are inhibited from multiplying. Therefore, food will not spoil and can be stored for a longer period of time.

5.What food products do freezer paper seal vs vacuum seal apply to?

Freezer paper seal and vacuum seal all play important roles in food packaging and storage field, can you tell what food products are they suitable for? Let’s discuss together.

Freezer Paper Seal

Freezer paper seal is suitable for storing all kinds of meat such as beef, chicken, duck, fish, etc, no matter they are fresh and frozen, besides, it can also pack all kinds of fried food and juicy food, which including French fries, meatloaf, sandwiches, fried chicken and so on. In a word, The food products that are common in your daily life all can be preserved by freezer paper seal.

Vacuum Seal

Relatively speaking, the scope of application of vacuum sealing is wider than that of freezer paper seal, in addition to meat food, vegetarian food can also be preserved. You can use vacuums seal to store raw and cooked meat, fish, vegetables, snacks, fruits, seafood, eggs, whole grains, soy products, convenience food and so on.

6.Which one can let food last longer in the fridge?Freezer paper seal or vacuum seal?

The answer of this question is vacuum seal, as a matter of fact, freezer paper seal is more suitable for short-term storage while vacuum seal is suitable for long-term. If you store a food product by a freezer paper seal, it can be stored in the fridge for 2 to 3 days, but if you choose vacuums seal, it can be stored for 2 weeks.

Why vacuum seal can let food last longer in the fridge than freezer paper seal? Well, vacuum seal completely isolated from food and air, as is known that it is the oxygen in the air provide survival environment of microorganism so that the food is spoiled. Vacuum seal provides a vacuum condition which doesn’t let microorganism survive and reproduce so that it can store food for long term.

On the contrary, although freezer paper seal also wraps the food and prevents it from the air, the package doesn’t as tight as vacuum seal, as a result, there will still be air contact with food, as time goes on, there will be food spoilage.

7.Which option can prevent food from freezer burns? Freezer paper seal or vacuum seal?

To figure out this question, you need to learn what is freezer burn first, it refers to a situation that the frozen food is exposed to the air so that it is dehydration and oxidation. Freezer burn is generally caused by loose packaging, therefore, vacuum seal can prevent food from freezer burns more effective than freezer paper seal.

On the one hand, vacuum seal stores food in a tight environment to prevent frostbite-causing crystals from forming on food. On the other hand, the vacuum seal bag which packs food is very thick and durable, provides good protection to food and prevents it from the air, so the moisture content of the food will not be evaporated, the food will not be freezer burned.

Of course that freezer paper seal also has the ability to prevent food from freezer burns, but the prerequisite is that it should be wrapped on the food very tightly, and it is best to use tape to fix it so that the food will not be exposed to the air. After all, freezer paper seal use freezer paper to wrap food, therefore, it is easy to be torn, so the anti-freezing effect is not as good as vacuum seal.

8.What are the differences between freezer paper seal and vacuum seal?

Besides the above content, there are also other differences between freezer paper seal and vacuum seal, such as prices, air removal abilities, sealing strengths and moisture resistance.

Prices

Prices

In terms of price, freezer paper seal costs less than vacuum seal, you can easily buy a lot of freezer paper in grocery stores or online, the price will not be too high. But, to use vacuum seal, you need to invest for a vacuum sealer.There are many vacuum sealers of different manufacturers and models on the market, and there are also various prices of them, but there is no doubt that their prices are far higher than those of freezer paper.

Air Removal Abilities

Vacuum seal has stronger air removal ability than that of freezer paper seal, because vacuum sealer is equipped with high suction vacuum pump which will extract all the air inside vacuums seal bag. But for freezer paper seal, actually it doesn’t have air removal ability, it just wrap the food and prevent it from the air, but once it is torn, the food will be exposed to the air again.

Sealing Strengths

Vacuum sealing has stronger sealing strength than freezer paper seal, vacuum sealer adopts heat sealing method to seal vacuum seal bags so that the sealing effect is good. However, if you want to use freezer paper seal, you need to use other tools such as tapes and straps, and the sealing strength is limited.

Moisture Resistance

Vacuum seal provides a tight seal to food, it can remove the extra moisture content of food and prevent it from the moisture in the air, but freezer paper seal can not. Freezer paper only has one side with plastic coating, the other side is paper, it is very easy for it to get wet, therefore, freezer paper seal doesn’t have moisture resistance.

Conclusion

After learning the detailed comparison of freezer paper and vacuum seal, how do you think of them? Which one of them do you think is better? To be honest, you can think about your real requirements, what kind of product do you need to store, which storage method is affordable for you. For more information, you can contact us and we will solve your problems at once.

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Author name: alei

Pharmacy Pill Counter: The Complete Buying Guide in 2025

1.What Is A Pharmacy Pill Counter?

2.Where Do You Use The Pharmacy Pill Counter?

3.How is Pharmacy Pill Counter Useful?

4.What are Pharmacy Pill Counter Components?

5.How to Classify a Pharmacy Pill Counter?

6.How is Pharmacy Pill Counter Work?

7.What Integrated Units of Pharmacy Pill Counter?

8.What Other Products Can Pharmacy Pill Counter Counts?

9.What Type of Packaging Material Can be Supported with Pharmacy Pill Counter?

10.What are the Problems and Troubleshooting of Pharmacy Pill Counter?

11.What Points to be Considered for Purchasing Pharmacy Pill Counter?

Conclusion

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Capsule Counting and Filling Machine: The Complete Buying Guide in 2025

1.What is Capsule Counting and Filling Machine?

2.What are industrial uses for Capsule Counting and Filling Machine?

3.What Is the Working of Capsule Counting And Filling Machine?

4.What Are the Major Parts of Capsule Counting and Filling Machine?

5.How Capsule Counting and Filling Machine Benefits You?

6.What are the Types of Capsule Counting and Filling Machine?

7.What is the Production line of Capsule Counting and Filling Machine?

8.What Type of Products Can Capsule Counting And Filling Machine Fill?

9.What Type of Packaging Material Capsule Counting And Filling Machine Can Fill?

10.How To Clean and Maintain Capsule Counting and Filling Machine?

11.What Are Common Problems and Troubleshooting of Capsule Counting And Filling Machine?

12.What Factors Should Be Considered Before Buying Capsule Counting and Filling Machine?

Conclusion

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Induction Cap Sealing Machine: The Complete Buying Guide in 2025

1.What Do You Know About Induction Cap Sealing Machine?

2.Where Is Induction Cap Sealing Machine Used?

3.How Does Induction Cap Sealing Machine Work?

4.How Induction Cap Sealing Machine Benefits You?

5.What Are Structural Parts of Induction Cap Sealing Machine?

6.What Is the Classification of Induction Cap Sealing Machine?

7.What Is The Production Line Of Induction Cap Sealing Machine?

8.How Does Induction Cap Sealing Machine Work with Different Caps Sizes?

9.What Types of Containers And Caps Are Compatible With Induction Sealing Machines?

10.What is the temperature of the induction Cap sealing Machine?

11.How To Clean & Maintain Induction Cap Sealing Machine?

12.Is Induction Cap Sealing Machine the Same as Heat Sealing Machine?

13.What Technical Problems You Face with Induction Cap Sealing Machine?

14.What Things Should Be Considered When Purchasing an Induction Cap Sealing Machine?

Conclusion

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Jar Filling Machine: The Complete FAQ Guide In 2025

1.What is jar filling machine?

2.What are the advantages of jar filling machine?

3.What industries are jar filling machine applied in?

4.What is the classification of jar filling machine?

5.What are the differences between jar filling machine and jar packing machine?

6.What components consist of a jar filling machine?

7.How does a jar filling machine work?

8.What factors can affect the filling speed of jar filling machine?

9.What kinds of products can be filled by jar filling machine?

10.What containers can be filled by jar filling machine?

11.What are the auxiliary equipment of jar filling machine?

12.Can jar filling machine be upgraded? And how?

Conclusion

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Desiccant Inserting Machine: The Complete Buying Guide in 2025

1.What Is Desiccant Inserting Machine?

2.What Is the Industrial Purpose of Desiccant Inserting Machine?

3.What Are the Benefits of a Desiccant Inserting Machine?

4.What Is Working of The Desiccant Inserting Machine?

5.How To Classify a Desiccant Inserting Machine?

6.What Is the Mechanical Structure of a Desiccant Inserting Machine?

7.What Types of Products Are Supported by A Desiccant Inserting Machine?

8.What Production line does a Desiccant Inserting Machine Support?

9.How to Maintain the Desiccant Inserting Machine?

10.What are the Technical Problems and Solutions of Desiccant Inserting Machine?

11.What Points to be Considered Before Purchasing a Desiccant Inserting Machine?

Conclusion

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