Applications

BREITNER – Your packaging task in the industry focus

BREITNER machines and systems mainly serve four industries: They are used in the food and cosmetics industry, in the chemical industry – especially in the cleaning agents segment – and in the pharmaceutical industry. With our decades of experience, we offer you the perfect solution for your specific requirements, for your products and their processing.

Each industry and each of its products has its own special features – find out more here.

FOOD

Typical products:
Vinegar, salad dressings, oil, liqueur, juices, jam, honey, nougat cream, jam, mustard.
Filling food means meeting a wide range of product characteristics. For example, low-viscosity products such as vinegar require completely different filling conditions than pasty foods, such as mayonnaise, which may still contain small pieces. Not to mention products that are filled warm, such as jam, or those that have to be processed under explosion-proof conditions, such as high-proof spirits.

Did you know that Scotch whisky is made from such pure water that inductive flow measurement cannot be used? Because it requires a minimum conductivity of the product of 50 µS/cm. Here BREITNER uses mass flow rate measurement.

Convince yourself of our range of machines.

In the chemical industry, our company serves a broad spectrum: our machines fill liquids for the automotive industry, cleaning chemicals or agrochemicals, to name just a few.

Some products, such as glass cleaners, are sometimes manufactured in large quantities, sometimes with special requirements, such as the shape of the bottle. A particular advantage of BREITNER machines is their high performance when filling highly foaming products.

When capping pump closures with dip tubes, our machines achieve particularly high cycle rates.

See our range of machines for yourself.

​CHEMISTRY

Typical products:
Engine oil, brake fluid, car care, petroleum, radiator antifreeze, windscreen cleaner, car wax, paints, glue, superglue, liquid fertiliser, disinfectant.

​CHEMISTRY

Typical products:
Engine oil, brake fluid, car care, petroleum, radiator antifreeze, windscreen cleaner, car wax, paints, glue, superglue, liquid fertiliser, disinfectant.
In the chemical industry, our company serves a broad spectrum: our machines fill liquids for the automotive industry, cleaning chemicals or agrochemicals, to name just a few.

Some products, such as glass cleaners, are sometimes manufactured in large quantities, sometimes with special requirements, such as the shape of the bottle. A particular advantage of BREITNER machines is their high performance when filling highly foaming products.

When capping pump closures with dip tubes, our machines achieve particularly high cycle rates.

See our range of machines for yourself.

COSMETICS

Typical products:
Shampoo, shower gel, hand soap, conditioner, roll-on deodorant, massage oil, nail polish remover, facial tonic, baby oil, hair tonic, sunscreen.
When filling and sealing cosmetic products, the full bandwidth of our machines becomes apparent. Foaming products or special closure shapes such as deodorant rollers do not pose any major challenges for us.

When it comes to cleaning these filling machines, however, CIP – Cleaning in Place – is often not enough. Instead, SIP – Sterilisation in Place – is used. Together with your process engineers, we will find the optimal solution for your very specific task.

See our range of machines for yourself.

BREITNER serves the area of non-sterile pharmaceutical and medical products with its filling machines.

In particular, we supply all the necessary documentation for pharmaceutical validation.

By the way: With our closing machines for tablet cans, we complement the filling machines for tablets from other manufacturers to form a complete filling line.

See our range of machines for yourself.

PHARMACY

Typical products:
Disinfectants, food supplements, remedies such as cough syrup or nasal spray.

PHARMACY

Typical products:
Disinfectants, food supplements, remedies such as cough syrup or nasal spray.
BREITNER serves the area of non-sterile pharmaceutical and medical products with its filling machines.

In particular, we supply all the necessary documentation for pharmaceutical validation.

By the way: With our closing machines for tablet cans, we complement the filling machines for tablets from other manufacturers to form a complete filling line.

See our range of machines for yourself.

CONTAINERS AND CLOSURES

Over the decades, our technicians have found solutions for processing pretty much every shape and design of container and closure.
These can be the smallest vials of 20 ml or large canisters of 40 litres. Occasionally the filling positions are further apart than the size of the bottle, or the task is to transport large and soft canisters that deform during the filling process and also spill over easily.

Sometimes bottles have three closures that have to be applied one after the other, or a curved dip tube has to be inserted into a PET bottle at high speed.

Right from the initial enquiry, we can give you very precise information on how we will design the machine to meet your requirements. As soon as we have your packaging materials, we will give you a binding statement on the design of the machine optimised for your needs, the output rate and the costs.

Containers and closures

These can be the smallest vials of 20 ml or large canisters of 40 litres. Occasionally the filling positions are further apart than the size of the bottle, or the task is to transport large and soft canisters that deform during the filling process and also spill over easily.

Sometimes bottles have three closures that have to be applied one after the other, or a curved dip tube has to be inserted into a PET bottle at high speed.

Right from the initial enquiry, we can give you very precise information on how we will design the machine to meet your requirements. As soon as we have your packaging materials, we will give you a binding statement on the design of the machine optimised for your needs, the output rate and the costs.

Single machines and lines

BREITNER supplies bottle unscramblers, filling machines and capping machines in a wide range of variants for different industries, products and container/closure shapes. They are coordinated with each other and work perfectly together in complete lines.
The bottle unscrambler conveys the bottles from a large storage bunker and places them in the correct position on the conveyor belt.
Bottles that do not have sufficient stability are inserted into a transport mould (puck) and then run stably through the filling line.

BOTTLE UNSCRAMBLER

Single machines and lines

BREITNER supplies bottle unscramblers, filling machines and capping machines in a wide range of variants for different industries, products and container/closure shapes. They are coordinated with each other and work perfectly together in complete lines.

BOTTLE UNSCRAMBLER

The bottle unscrambler conveys the bottles from a large storage bunker and places them in the correct position on the conveyor belt.
Bottles that do not have sufficient stability are inserted into a transport mould (puck) and then run stably through the filling line.

FILLING MACHINES

The choice of the right machine must be matched to the different products and pack shapes as well as to the different requirements of the filling process – especially the required cycle rates. Here are the two most important decision criteria:

  • For homogeneous liquids, flow metering is the best choice; for chunky (jam) or very pasty products (creams), a piston filler is the better choice.
  • For very high cycle rates, a rotary filler is the best choice; below the order of magnitude of approx. 130 packs per minute, a linear filler is more cost-effective and also more flexible to convert.

In addition, there is a whole range of other variants and options with which we can tailor the machine to your requirements:

  • The TWIN machine model has two parallel belts on which to fill. This doubles the production rate and delivers an almost continuous output due to the alternating cycle between the two belts.
  • Peristaltic pumps are suitable for special applications. When filling superglue, the piece of tubing with the solidified adhesive can simply be disposed of after (unforeseen) machine downtime. Cleaning the machine parts would be problematic or impossible.
  • For different products, we offer containers and the product guide in many variants and additional equipment. Plastic/titanium for acids, heating or an agitator for hot filling or inhomogeneous products. More about this below.
  • Different containers require different handling. We offer solutions for particularly small bottles, for particularly large ones or even soft canisters that deform during filling.

Talk to us.

When it comes to closing the containers, the range of requirements is similarly high as for filling. Here are the most important aspects:

  • Is the closure screwed on or pressed on? What shape is the closure – is it easy to grip mechanically?
  • Our machines have particular advantages when it comes to pump closures with dip tubes, which have to be threaded quickly and precisely into the narrow bottle mouth.
  • Is there only one cap, or are there also droppers to be pressed in or dust caps or measuring cups involved? Our machines can apply up to three caps in total.
  • Are canisters being screwed on that would tend to spill over if stopped abruptly at a screwing station? It is best to run them through the machine without any jerks and to close them during this process.

Analogous to filling machines, rotary closing machines are best suited for very high cycle rates. We can currently accommodate up to 12 closing stations in one machine. The throughput here is correspondingly high.

CLOSING MACHINES

CLOSING MACHINES

When it comes to closing the containers, the range of requirements is similarly high as for filling. Here are the most important aspects:

  • Is the closure screwed on or pressed on? What shape is the closure – is it easy to grip mechanically?
  • Our machines have particular advantages when it comes to pump closures with dip tubes, which have to be threaded quickly and precisely into the narrow bottle mouth.
  • Is there only one cap, or are there also droppers to be pressed in or dust caps or measuring cups involved? Our machines can apply up to three caps in total.
  • Are canisters being screwed on that would tend to spill over if stopped abruptly at a screwing station? It is best to run them through the machine without any jerks and to close them during this process.

Analogous to filling machines, rotary closing machines are best suited for very high cycle rates. We can currently accommodate up to 12 closing stations in one machine. The throughput here is correspondingly high.

Packaging lines

In our packaging lines, we integrate the bottle unscrambler, filling and closing machine into a complete line. These machines are perfectly matched to the product, the container, the closure and, last but not least, to all the components in the line. This goes beyond optimising the cycle rate. You get the complete solution from a single source. Optimised. Guaranteed.

Interfaces to subsequent machines

We are happy to coordinate the interface to subsequent machines such as labellers or machines for final packaging, e.g. in cartons, with you or the supplier of these machines.

Here we have many years of experience and know what is important.

Filling and closing in production – our experience for your application

At first glance, it is quite simple: The product enters the bottle or canister via a filling nozzle. The container is then screwed down. In the following, we would like to describe a few special features of these processes. Special requirements for the process result from the product itself and its properties, the containers, but also from the production processes in your company.

We are equipped for all these special requirements with our machine technology. Our technicians can advise you based on our decades of experience – and they are guaranteed to find a customised solution for you.

The filling nozzle and the filling level

When filling thick tomato sauce, the filling nozzle is always just above the filling level – and thus remains clean.
During filling, the liquid level in the bottle rises. The exact position of the filling nozzle relative to the filling level is decisive for the quality of the filling and for the filling speed. The properties of the product also play an important role.

The BREITNER machine control allows settings that make the filling process particularly clean and fast:

  • Overspill filling
    the opening of the filling nozzle is always at the same distance above the liquid level. This is also the case with waisted bottles (moulded bottles), where the rise of the liquid level varies during the filling process.
  • Filling below the level
    Here the opening of the filling nozzle is always just below the level of the liquid. This makes it easy to fill even highly foaming products.

Intermittent or continuous operation during filling?

Intermittent or continuous operation during filling? The BREITNER machine control system covers two operating principles:

  • Linear filling and closing machines – they operate intermittently.
  • Rotary filling and closing machines – they operate continuously.

Here is a closer look at these two operating principles.

Our linear filling and closing machines operate in intermittent mode. A continuously running conveyor belt conveys the packs into the machine.

In the filling machines, several containers are stopped under the filling nozzles, the filling nozzle lowers into the bottle or canister mouth and the filling process begins. When the container is full, the bottles are transported further.

In the case of the closing machines, each bottle is gripped, stopped and screwed down individually by means of a so-called transport starwheel.

Intermittent operation

This stopping slide in reinforced design is practical for large bottles or canisters – when filled, they are held reliably and precisely.
Typical transport star in a rotary closing machine. The screw capping station is located at the back in the middle.

Intermittent operation

This stopping slide in reinforced design is practical for large bottles or canisters – when filled, they are held reliably and precisely.
Typical transport star in a rotary closing machine. The screw capping station is located at the back in the middle.
Our linear filling and closing machines operate in intermittent mode. A continuously running conveyor belt conveys the packs into the machine.

In the filling machines, several containers are stopped under the filling nozzles, the filling nozzle lowers into the bottle or canister mouth and the filling process begins. When the container is full, the bottles are transported further.

In the case of the closing machines, each bottle is gripped, stopped and screwed down individually by means of a so-called transport starwheel.

Continuous operation

The bottles run continuously through the machine: from the left into the infeed starwheel, in the middle through the central starwheel and on the right via the outfeed starwheel back onto the conveyor belt. The capping spindles work synchronously with the central starwheel; the caps (yellow) are fed in from the right.

With our rotary filling and closing machines, the bottles run continuously through the machine without stopping – and thus jerk-free. The machine throughput per hour is higher, this process is suitable for large production volumes.

The decision: Intermittent or continuous?

It depends on numerous parameters of your production, your containers and the product. The production conditions, such as the frequency of batch changes, also play a decisive role here.

We advise you on which process makes the most technical sense for your production, but is also the most economical. In our extensive range of machines, you will find the right machine for your requirements in the optimum design and combination with other machines.

Cleanliness during filling

Cleanliness: Cleanliness is an absolute must when filling. We have the necessary technology to ensure that canisters do not spill over during transport and that nothing drips out of the filling nozzle – onto the conveyor belt, for example. We have decades of experience in optimising these processes, and our engineers put our accumulated know-how at your disposal.

Cleaning: In most cases, the filling machine has to be cleaned at regular intervals, e.g. at the end of a production shift.

This means that the machine does not have to be dismantled for cleaning, but a cleaning and rinsing fluid cleans the machine from the inside.

What exactly does this cleaning process look like? How consistently should the process be automated? What happens to the cleaning medium – is it recycled and disposed of?

We offer you the full variety of technical possibilities.

All these questions depend on the product, environmental requirements for your production plant and the desired degree of automation.

CIP – Cleaning in Place

typisches CIP Schema im Überblick mit Spültulpen und Sammelbehälter
From our offer: Typical CIP scheme with cleaning cups at the filling positions and a central collection tank.

CIP – Cleaning in Place

typisches CIP Schema im Überblick mit Spültulpen und Sammelbehälter
From our offer: Typical CIP scheme with cleaning cups at the filling positions and a central collection tank.
This means that the machine does not have to be dismantled for cleaning, but a cleaning and rinsing fluid cleans the machine from the inside.

What exactly does this cleaning process look like? How consistently should the process be automated? What happens to the cleaning medium – is it recycled and disposed of?

We offer you the full variety of technical possibilities.

All these questions depend on the product, environmental requirements for your production plant and the desired degree of automation.

SIP – Sterilization in Place

SIP Labortest
The set-up of a cell culture proves the success of the Sterilisation in Place (SIP) cleaning of the filling machine.
For some products, CIP – Cleaning in Place – is not sufficient – the product guidance must be absolutely sterile. “Absolute” means that only a very small amount of residual germs may remain in the machine; this must be regularly checked and recorded in the laboratory.

We provide the necessary technology for sterilising the product guide with superheated steam and for sterilising the compressed air used via activated carbon or sterile filters.

The staff of your laboratory and our machine technicians work closely together. This ensures success for sterile operation in your production.

In the case of perishable foodstuffs (such as special sauces, freshly squeezed fruit juices, etc.), the requirements for low germ contamination during filling are so high that the ambient air must be under control of the germ contamination even on the short distance between the opening of the filling nozzle and the liquid level in the bottle. In such cases, we equip the filling machine with an additional filter device – Laminar Airflow – which supplies the machine’s working chamber with sterilised air.

Germs do not float freely in the air on their own, but are attached to dust and other tiny air particles; as these particles are retained by the Laminar Airflow filters, the germ load is also reduced.

Filtered air around the filling nozzle – Laminar Airflow

laminar Airflow

Gefilterte Luft rund um das Füllrohr – Laminar Airflow

laminar Airflow
Bei verderblichen Lebensmitteln (etwa speziellen Saucen, frischgepressten Obstsäften, etc.) sind die Anforderungen an eine niedrige Keimbelastung beim Abfüllen so hoch, dass die Umgebungsluft selbst auf der kurzen Strecke zwischen Füllrohrmündung und Flüssigkeitsspiegel in der Flasche die Keimbelastung unter Kontrolle sein muss. In solchen Fällen statten wir die Abfüllmaschine mit einer zusätzlichen Filtereinrichtung – Laminar Airflow – aus, die den Arbeitsraum der Maschine mit entkeimter Luft versorgt.

Keime schweben nicht alleine frei in der Luft, sondern hängen an Staub und anderen kleinsten Luftpartikeln; weil diese Partikel durch die Filter des Laminar Airflow zurückgehalten werden, sinkt auch die Keimbelastung.

Explosion-proof operation during filling

Products such as disinfectants or nail polish remover contain alcohol or solvents and are therefore highly flammable. They must be filled under explosion protection conditions (ATEX).
Ex-Schutz
We supply the entire technology of the explosion protection equipment for our machines from a single source. This starts with the special mass flow meter and extends to the gas warning device in the working chamber.

The project planning includes, among other things, the definition of the zoning, but also all official verifications and, of course, the tailoring to the explosion protection situation in your production, right up to the ventilation of the hall.

In the quotation phase, we coordinate the machine design with your conditions in detail.

Specific porduct properties

So far, we have assumed – for the sake of simplicity – that the product is filled at room temperature and is also completely homogeneous.

But even here there are particularities to be considered.

Some products, such as honey, are filled warm – they are then thinner and can thus be filled more quickly and cleanly.

Jam or certain sauces are filled hot (typically above 80°C) to reduce germ contamination and thus improve shelf life.

Because viscosity is highly temperature-dependent, it is crucial for the precise filling process that the product in the product container is kept at a very even and constant temperature and protected from cooling.

Our double-walled and heated product vessel, possibly with an agitator to distribute the supplied heat, ensures a constant temperature throughout the vessel.

Hot filling

Marmelade wird immer heiß abgefüllt
The industrial process is no different from grandma’s method: hot filling is sterile and ensures shelf life.

Hot filling

Marmelade wird immer heiß abgefüllt
The industrial process is no different from grandma’s method: hot filling is sterile and ensures shelf life.
Some products, such as honey, are filled warm – they are then thinner and can thus be filled more quickly and cleanly.

Jam or certain sauces are filled hot (typically above 80°C) to reduce germ contamination and thus improve shelf life.

Because viscosity is highly temperature-dependent, it is crucial for the precise filling process that the product in the product container is kept at a very even and constant temperature and protected from cooling.

Our double-walled and heated product vessel, possibly with an agitator to distribute the supplied heat, ensures a constant temperature throughout the vessel.

Lumpy and sedimentary products

Stückiges Produkt: Himbeermarmelade
The small pieces of fruit in this high-quality raspberry jam are easily recognisable.
Jam or sauces, for example for fondue, present special challenges for the filling process: Small pieces of fruit, which make up a high-quality jam, or sauces, which easily break down into their fat- and water-containing components, must be kept moving in the product vessel until the last moment before filling.

An agitator, mounted at the top or bottom of the product vessel, ensures uniform mixing.

Which speed and which shape of agitator blade is appropriate? Your specialists and ours jointly determine this technical design. Here, too, we have decades of experience and can therefore advise you perfectly.

A piston filling machine is suitable for lumpy mixtures.

Transport mould – the puck

Some bottles do not stand reliably on the conveyor belt: they are too small, too light, have a sloping base or are top-heavy
In all these cases, each bottle is placed in a transport mould in which it goes through the entire process – filling and closing. Before packing, the bottle is removed from the transport mould, which runs back to the bottle unscrambler.

At a low output in the filling process, the bottles can be set up manually together with the puck. For higher outputs, we recommend our bottle unscrambler with integrated mould inserter (type BFP).

Puck mit Flasche - 3D-Entwurf
This puck was specially milled for one of our customers so that it can also be easily processed by the downstream labeller.
Ex-Schutz
This puck was specially milled for one of our customers so that it can also be easily processed by the downstream labeller.
In all these cases, each bottle is placed in a transport mould in which it goes through the entire process – filling and closing. Before packing, the bottle is removed from the transport mould, which runs back to the bottle unscrambler.

At a low output in the filling process, the bottles can be set up manually together with the puck. For higher outputs, we recommend our bottle unscrambler with integrated mould inserter (type BFP).

Interested? Then please contact us!

Our team will gladly answer your questions.

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