Automated filling systems are dependent upon the compatability of the filling equipment and the packaging material used for filled products. This article explores the process of determining the correct spout diameter for use on spouted pouches in high speed automated production lines, as well as how that will reduce downtime and improve your line’s OEE (Overall Equipment Effectiveness) through accurately specifying product requirements.
The Core Bottleneck of Automated Filling: Why Spout Specifications Determine Output Rate?
For manufacturers using automated filling lines, spouted pouches are not just a packaging bag; they are a crucial link in the precise cycle of the production line. Even small deviations in spout diameter or neck size can be magnified into serious production failures at high speeds of 60-120 bags per minute.
1. Gripper and Rail Compatibility
Automated filling machines transport spouted pouches via rails. If the outer diameter (OD) of the spout neck does not match the rail gap:
- Outer diameter too large: This will cause bag jamming, leading to frequent alarms and shutdowns of the filling line.
- Outer diameter too small: The packaging bag will wobble during movement, preventing the filling needle from accurately aligning, resulting in significant material splashing and waste.
2. Matching Data Reference for Filling Needle and Inner Diameter
To ensure that no back pressure or liquid splashing occurs during high-speed filling, the outer diameter of the filling needle must have sufficient clearance from the inner diameter (ID) of the spouted pouch spout.
| Filling Line Speed (BPM) | Recommended Nozzle Inner Diameter (ID) | Recommended Filling Needle Outer Diameter | Typical Applicable Products |
|---|---|---|---|
| 30-50 BPM | 8.5mm | 6.5mm | Mineral water, clear fruit juice |
| 60-80 BPM | 10.0mm | 8.0mm | Probiotic drinks, light hand sanitizer |
| 80-120+ BPM | 13.0mm – 16.0mm | 11.0mm | Concentrated laundry detergent, high-viscosity sauces |
3. Heat Sealing Pressure and Post-Filling Air Release Control
At the end of the automated production line, spouted pouches usually require displacement or initial pressure sealing before capping. If the nozzle diameter is not matched to the product viscosity, it can lead to incomplete air removal from the bag. During high-speed capping, the increased internal pressure may cause “micro-leakage” at weak points in the bag. Stanley Package’s customized nozzle design effectively optimizes the air release path, ensuring a high sealing rate.
4. Solving “Stringing” and “Wall Adhesion”: The Killers of Automated Production
In the automated filling of high-viscosity products, the diameter of the spouted pouch directly affects the liquid cutoff effect.
- Phenomenon: If the diameter is too small, “stringing” will occur at the end of filling, with sauce dripping onto the nozzle threads.
- Consequences: Contaminated threads can lead to loose caps or contaminated seals, ultimately resulting in the entire batch of products leaking and being scrapped during transportation.
Why Do Leading Brands Choose Stanley Package?
When operating in an automated packaging production process, there is virtually zero tolerance for error. As a premier Fabricante de envases flexibles a medida, Paquete Stanley has been providing high-precision adaptation solutions to brands worldwide since 1998.
- High-Precision Tolerance Control: Every batch of spouted pouches we produce undergoes rigorous dimensional verification, ensuring spout tolerances are within specified ranges, perfectly compatible with various imported (such as Italian, Japanese, and German) automatic filling machines.
- Hardware-Level Compatibility Recommendations: Stanley Package doesn’t just supply bolsas de envasado; our technical team can reverse-engineer the most suitable coefficient of friction (COF) for roll stock packaging film based on your filling machine model, preventing stretching and deformation during automatic bag making from roll stock.
- Green and Efficient Production: In our 15,000 square meter factory, our RTO system ensures a clean production environment. This is not only an environmental requirement but also a fundamental quality standard to ensure our food-grade spouted pouches are odorless and contaminant-free.
Improve Your Production Line Efficiency
Is your filling line frequently experiencing downtime due to packaging compatibility issues?
Póngase en contacto con Paquete Stanley, and let our engineers evaluate your existing spouted pouches solution. We can provide customized sample bags that meet your automation parameters for on-machine testing.
