Description

High-Security Rotary Bottling System for Chemical Products

🧴 RC-100 monoblock is a specialized rotary system designed for rinsing, filling, and capping liquid soap and other foaming products.

RC-100 Liquid Soap & Foaming Products Bottling Triblock System.

Chemical Resistance & Compatibility.

Hazardous Material Handling Technology.

Foam Control Technology.

Precision Filling with Volumetric Accuracy.

Corrosion-Resistant Design & Construction.

The RC-100 monoblock is a robust and versatile solution for manufacturers of liquid soaps and foaming products. Its advanced foam control, precision filling, and compliance with industry standards make it suitable for a range of applications.

Foam Management Technology

The RC-100 incorporates specialized foam control technology that addresses the unique challenges of filling foaming products like liquid soaps. The system features anti-foaming filling nozzles that minimize air incorporation during the filling process, preventing excessive foam formation that can lead to inaccurate fills and production delays. The programmable filling cycles allow for customized fill speeds and patterns that can be optimized for different product formulations and foam characteristics.

The system’s vacuum-assisted filling technology helps to maintain product integrity by preventing aeration during the transfer process. This is particularly important for products containing surfactants and foaming agents that are prone to excessive bubbling. The equipment can handle various product viscosities ranging from thin liquid soaps to thicker gel formulations, making it versatile for different product lines within a manufacturing facility.

Precision Filling System

The RC-100’s volumetric filling system ensures accurate dosing with precision within ±0.5% of set volume, maintaining consistency across various product viscosities and foam characteristics. The system features quick-change parts that allow rapid format adjustments between different container sizes and product types, minimizing downtime during production changeovers.

The filling technology handles various product types including:

• Liquid soaps: Hand soaps, body washes, and specialty cleansing products

• Foaming products: Foaming hand soaps, shaving creams, and mousse products

• Personal care products: Shampoos, conditioners, and shower gels

• Household products: Dish soaps, surface cleaners, and detergents

Corrosion-Resistant Construction

The system is constructed with AISI 304/316L stainless steel throughout all product contact surfaces, providing excellent resistance to the corrosive effects of soap formulations and cleaning products. The container rinsing module utilizes high-pressure air or water jets to ensure perfect cleanliness before filling, removing any particulate matter or contaminants that could affect product quality.

For operations requiring enhanced hygiene, the system can be equipped with additional features such as:

• CIP (Clean-in-Place) systems for automated cleaning without disassembly

• Specialized surface finishes that resist product adhesion and facilitate cleaning

• Drainage systems designed to handle liquid runoff during cleaning procedures

• Corrosion-resistant coatings on all exposed surfaces

Applications & Industry Solutions

Personal Care Product Applications

The RC-100 is particularly suited for personal care product packaging with its ability to handle various foaming and liquid products including:

• Liquid soaps: Hand soaps, body washes, and specialty cleansing products

• Foaming products: Foaming hand soaps, shaving creams, and mousse products

• Hair care products: Shampoos, conditioners, and styling products

• Skin care products: Lotions, creams, and specialized treatments

The system’s precision filling ensures consistent fill levels, while the foam control technology maintains product quality and appearance throughout the packaging process.

Household Product Applications

Beyond personal care, the RC-100 handles various household cleaning products:

• Dish soaps: Liquid dishwashing detergents and automatic dishwasher detergents

• Surface cleaners: All-purpose cleaners, bathroom cleaners, and kitchen sanitizers

• Laundry products: Liquid detergents, fabric softeners, and stain removers

• Specialty cleaners: Glass cleaners, floor cleaners, and disinfectant products

Our advanced rotary bottling triblock integrates multiple essential operations in a single automated platform for efficient and safe packaging of various chemical products. Specifically engineered for household chemicals, automotive chemicals, industrial chemicals, and agrochemicals, this system handles aggressive, toxic, and foaming products with specialized safety features.

Technical Configuration

• Rotary Bottle Rinsing Module: High-pressure cleaning system

• Precision Rotary Dosing System: Corrosion-resistant filling technology

• Orbital Cap Orienter: Disc-type cap sorting with elevator feed system

• Rotary Capping Station: Secure sealing for hazardous materials

• Safety Guarding System: Complete perimeter protection with interlocks

Key Specifications

Specialized Features

• Chemical Resistance: 316L/904L stainless steel construction

• Vapor Management: Integrated fume extraction systems

• Explosion-Proof Options: ATEX certification available

• Precision Filling: ±0.5% accuracy for costly chemicals

• Quick-Change System: Rapid format adjustments

• CIP/SIP Capability: Clean-in-Place/Sterilize-in-Place systems

Safety & Compliance

• Leak Detection: Advanced sealing integrity verification

• Vapor Containment: Closed system for toxic fumes

• Emergency Stop: Multiple emergency stop buttons

• Chemical Compatibility: Certified for aggressive substances

• Regulatory Compliance: Meets international safety standards (OSHA, EU directives)

⚙️ 1. Technical Specifications and Design

• Capacity: The machine can handle up to 5,000 bottles per hour for automatic operations, with lower capacities (200-500 bottles/hour) for semi-automatic models.

• Bottle Compatibility: Designed for PET and HDPE containers ranging from 0.1L to 5.0L, with adaptability to various bottle sizes and neck diameters.

• Filling Technology: Utilizes piston filling systems for high accuracy, with dosing precision of ±0.5% to minimize product waste.

• Capping System: Equipped with automatic screw capping for plastic caps, including torque control to ensure secure sealing.

• Construction: Built from chemical-resistant materials such as 316L stainless steel and PTFE seals to withstand aggressive substances like detergents and soaps.

• Power Requirements: Typically operates on 380V/50Hz three-phase power, with options for other voltages based on regional requirements.

🔄 2. Key Features and Process

• Integrated Operations: Performs rinsing, filling, and capping in a single unit, reducing contamination risks and saving floor space.

• Anti-Foaming Technology: Specialized filling valves and slow-fill settings minimize foam generation during the filling process, crucial for liquid soaps and detergents.

• Precision Dosing: Piston fillers ensure accurate volume control, with options for weight-based dosing for high-value products.

• Hygiene and Maintenance: Designed for CIP (Clean-in-Place) capabilities, allowing easy cleaning without disassembly.

• Advanced Controls: Features a PLC with touchscreen interface for adjusting parameters (e.g., fill volume, capping torque) and storing recipes. Options for remote monitoring and automation integration are available.

🧼 3. Applications and Use Cases

• Liquid Soaps and Detergents: Ideal for hand soaps, dish detergents, and shampoos requiring precise filling and foam control.

• Household Chemicals: Suitable for cleaning products, disinfectants, and other foaming liquids.

• Cosmetics and Personal Care: Handles body washes, shower gels, and other viscous foaming products.

• Industrial Products: Adaptable for lubricants, solvents, and specialty chemicals with foaming tendencies.

💎 4. Advantages and Compliance

• Foam Control: Specialized systems minimize product loss and ensure accurate fills, even with high-foam products.

• Flexibility: Quick changeover between container sizes and products, reducing downtime.

• Safety and Compliance: Meets international standards for chemical equipment (e.g., CE marking), with options for explosion-proof components for flammable products.

• Cost-Effectiveness: High-speed operation and reduced product giveaway lower operational costs.

📦 5. Optional Accessories and Customization

• Nitrogen Flushing: Inert gas injection to prevent oxidation and foam generation.

• UV Sterilization: For cap and bottle sanitization before filling.

• Labeling Integration: Compatible with inline labelers for complete packaging solutions.

• Customizable Controls: UL/CSA-compliant electrical systems for specific regional markets.

The system’s corrosion-resistant construction and sealing technology make it particularly suitable for household products where package integrity and leakage prevention are critical considerations.

📜 Schedule virtual airflow visualization test.

💡 Mention your: Target market (EU/US/Global South), Active ingredient, Required throughput.

🔬 Schedule virtual factory acceptance test with our engineers.

🏷️ Request Compliance Audit: Free gap analysis with throughput simulation.

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