Articles · Technology · 2026-09-13
How a custom filling line is designed: from product data to production
A custom line fails when the design starts with the machine instead of the product. This is the process we follow to keep it the other way around.
Step 1 — Build the product data sheet
Every custom line starts with four answers: product type and viscosity, fill volume, container and required output. Around them we add temperature, particle size and shape, shear sensitivity, foaming tendency, hygiene class and cleaning regime. This one sheet decides everything downstream — pump type, contact materials, nozzle design, line speed and CIP configuration.
Step 2 — Choose the dosing principle
Pump type is an output of product data, not a company preference. In broad terms:
| Product profile | Typical dosing pump |
|---|---|
| Thin liquids (oil, beverages) | Gear pump filler |
| Simple, robust low-cost dosing | Piston pump filler |
| Shear-sensitive pastes and creams | Screw pump filler |
| High viscosity, particles, wide fill range | Rotor pump filler (metering grade) |
Step 3 — Design the line layout
We then map the complete flow: product feed and conditioning, the filling station, container handling, capping or sealing, labelling, and downstream packing. Bottle or jar shape, neck size and material all affect the filling nozzle and handling rails. Layout is planned for realistic operator access, cleaning paths and future capacity — not just the tightest footprint.
Step 4 — Integrate control and data
A modern line is a small factory network. Servo dosing parameters, changeover recipes, counting and quality data should connect to your line control. We plan the integration in the design phase so that data logging and changeover don't become retrofit projects later.
Step 5 — Test, build, commission
Where the product is unusual, we run a filling test before quoting the final machine, then again at factory acceptance with your product. Installation and commissioning cover line balancing, operator training and a documented acceptance test — product, fill volume, speed and accuracy, measured on real samples.