What is the most afraid of the filling workshop? It's not the roar of the machine, it's not the explosion of orders, it's the sudden "hand shaking" of the liquid filling and packaging machines on the assembly line-it's clearly set to 500 ml, but the filling is either 495 or 510! Last week, a jam factory in Zhejiang was detained at the customs because of excessive errors. The boss rushed into our workshop with samples overnight.
1. Where does the error come from? The sensor "lies" is the culprit
Lao Zhang, who has been working in debugging for eight years, often says: "Filling errors are like catching a cold. The symptoms are all inaccurate measurements, but the causes are different." Our factory's liquid filling and packaging machine uses a high-precision flow meter + weighing sensor double insurance, but over time, the sensor will inevitably "lie."
Last month, when we overhauled a shampoo factory in Guangdong, we found that their equipment error had soared to ±3%! When we opened it, we found that the sensor probe was stuck with semi-solidified aloe vera gel, like a layer of transparent armor. Under such conditions, let alone accurate filling, it would be lucky to be able to start the machine normally.
Two, three-step calibration method, let the equipment "tell the truth" again
For this type of problem, our factory has explored a set of "look, smell, ask, and feel" calibration methods:
. Reset the dynamic weighing module - first run it without load to let the liquid filling and packaging machine self-check to zero, and then hang a standard weight for verification. It's like "brainwashing" an electronic scale, forcing it to forget its previous wrong memory.
.Temperature compensation debugging——The calibration parameters for filling glacial acetic acid and hot honey are completely different. We will repeatedly test the sensitivity of the sensor with glycerin simulation liquid at the actual production temperature of the customer.
.Actual simulation filling——Take real materials to do 10 sets of continuous filling, eliminate the head and tail fluctuation data, and take the middle 8 sets to calculate the average error. After trying this trick, Mr. Li from the cosmetics factory exclaimed: "It's more accurate than a fortune teller!"
3. "Life-saving" case of chemical plants
The most amazing one was the emergency failure of a pesticide factory in Inner Mongolia last year. Their liquid filling and packaging machine always had a difference of 5 ml when filling herbicides, and the agricultural service station almost tore up the annual order. Our technical team went to the site and found that the highly corrosive gas corroded the sensor circuit board into verdigris!
Anti-corrosion sheaths were installed on the equipment overnight, and the sensor probe was wrapped with Teflon coating. After calibration, concentrated sulfuric acid was used for limit testing, and the error was stable within ±0.5% after 300 fillings. Now the factory brags to everyone: "This equipment is more durable than a camel!"
Fourth, daily maintenance is more important than calibration
In fact, calibration is like measuring blood pressure. You can't wait until you get sick to measure it. We recommend that users do basic calibration once a quarter:
· Use a medical syringe to extract the finished filling product and reversely calculate the actual capacity
· Observe the dripping of the liquid filling and packaging machine when it stops. If it exceeds 3 drops, repair it immediately
· Regularly wipe the surface of the sensor with anhydrous ethanol to prevent interference from sugar and grease
A Beijing essential oil factory strictly implements this plan. The error of the equipment has been controlled within ±1% for five years. The workshop director Lao Wang also invented the "sound identification method"-the equipment with normal filling will emit a regular buzzing. Once the sound changes, it is likely that the sensor is "angry".
Conclusion
Filling accuracy is the lifeblood of the liquid filling and packaging machine, and the sensor is the "golden finger" that controls the lifeblood. Today, our factory has shaken back the calibration experience accumulated over 20 years of hard work. If you are worried about filling errors, you might as well try these folk methods. Of course, if you encounter any tough problems, you are always welcome to come to the workshop to find Lao Zhang - even the Maotai Distillery cannot find any fault with the equipment he has calibrated!
