Filling a foaming product may seem simple: all you need to do is introduce the desired quantity into the container. In practice, however, foam formation can quickly make the process more complicated. The product may rise, overflow, give the impression of an incorrect fill level or make accurate dosing more difficult to control.
This issue concerns many types of products, including detergents, liquid soaps, certain cosmetic products, cleaning products and some food formulations.
To achieve consistent, controlled filling, it is therefore essential to take the actual behaviour of the product into account and adapt the dosing technology, filling parameters and various components, such as the filling nozzles.
Why do some products foam during filling?
Not all products behave in the same way. Two liquids with a similar viscosity may react very differently when it comes to foam formation. The product formulation therefore plays an important role, but the way the product is transferred into the container can also increase or reduce the phenomenon.
This is why knowing the general nature of the product is not enough to choose a filling machine. Its behaviour must be observed under actual dosing conditions.
Filling speed
Filling speed can influence the behaviour of the product. Filling too quickly can promote turbulence and air incorporation, depending on the characteristics of the formulation. However, systematically slowing the machine down is not necessarily the best solution.
The aim is to find the right balance between filling speed and product behaviour in order to achieve consistent dosing while maintaining a production rate that is in line with the company’s objectives.
Choosing the right filling nozzle
The filling nozzle forms the interface between the filling system and the container. Its design and use must be adapted to the product being filled.
We have also dedicated an article to different filling nozzles depending on the products, as the characteristics of the product directly influence the choice of this component.
For foaming products, controlling the flow and the way the product enters the container are particularly important. Depending on the application, different configurations can be considered to limit turbulence and promote more consistent filling.
Filling with a diving nozzle
A diving nozzle can limit the distance the product falls and can therefore help reduce foam formation. The principle consists of bringing the point at which the product is introduced closer to the bottom of the container, then adapting the movement of the nozzle as the container is filled. This solution is particularly useful when the product foams easily and the container configuration is suitable for it.
However, the choice of system must be made on a case-by-case basis. A diving nozzle is not automatically necessary.
Filling machines suitable for foaming products
There is no universal filling machine for all foaming products.
For small or medium-scale production, a semi-automatic filling machine can be a suitable solution. For larger production volumes, filling can be integrated into an automated line.
Our K-Net is a semi-automatic filling machine designed for different types of products, including fluid, viscous and pasty products. It can also be configured with different dosing systems depending on the nature of the product.
Our K-Line S is an automatic filling machine that can be equipped with diving nozzles. Numerous options can be added to ensure that it perfectly meets a wide range of filling requirements. This filling machine can also be integrated into a complete line.
Why are trials particularly important when filling a foaming product?
A foaming product can behave differently depending on the filling speed, dosing system, container and nozzle configuration.
This is why a trial carried out with the product and the container can provide particularly useful information. During a trial, several factors can be observed:
- foam formation;
- how quickly the foam appears;
- how it develops during filling;
- the behaviour of the product as it approaches the final fill level;
- any splashing;
- dosing consistency;
- the influence of different settings.
These observations can then be used to determine a configuration that is consistent with the project’s objectives.
Does your product foam during filling? Contact us to discuss its characteristics, your containers and your production objectives. We can work with you to assess the most suitable dosing technology and configuration for your project.
FAQ: Filling foaming products
How can you prevent a product from foaming during dosing?
The dosing technology and filling parameters must be adapted to the characteristics of the product. Depending on the application, the choice of nozzle, filling speed or a suitable filling system can help limit foam formation.
Can a foaming product be filled automatically?
Yes. Some filling machines can handle foaming products. However, the configuration must be adapted to the product, the container and the filling requirements.
Can the K-One fill a foaming product?
Yes, the K-One can dose low-foaming products. Appropriate settings can help limit foam formation during filling.
Is the K-Line S suitable for foaming products?
Yes. The K-Line S is designed for liquid, foaming or thick products. It can notably be fitted with a diving nozzle as an option.
Do you need to slow down a machine when filling a foaming product?
Not necessarily. Reducing the speed can help limit foam formation, but it is preferable to assess the entire filling system in order to find a setting suited to the product and the required production rate.
Why carry out a filling trial?
A trial makes it possible to observe the actual behaviour of the product with the intended machine, filling nozzle and container. It helps determine the most suitable settings and configuration.
Are cleaning products particularly affected by foaming?
Some cleaning products, such as cleaning agents, can indeed be foaming. However, their behaviour depends on their formulation.
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The Specific Requirements of Household Product Packaging
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Which Machine Should You Choose to Package Multiple Formats on the Same Production Line?
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How can cleaning products and detergents be packaged efficiently?
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CDA, almost 10 years of filling
