Brief description
This service aims to minimise sloshing when handling liquid products on high-speed filling lines. When liquid is dispensed into containers at very high speeds, for example in the production of beverages, dairy products or pharmaceuticals, splashing inevitably occurs. This can result in product loss, contamination of equipment and the work area, reduced hygiene standards and inaccurate dosing of the finished product.
Benefits for the customer
Reduced product losses
By optimising the flow profile, the liquid is delivered precisely into the container with almost no spillage. This increases the yield of saleable products and reduces raw material losses.
Cleaner equipment means less downtime
Minimising splashes prevents the contamination of bottles (containers) and surrounding equipment, thereby reducing downtime for cleaning and sanitising the production line.
High production hygiene
The absence of spills and drips ensures compliance with strict sanitary regulations, which is particularly important in the food and pharmaceutical industries.
Accurate dosing
Intelligent filling control ensures that each container receives the specified volume of product without foam or underfill, guaranteeing consistent quality and adherence to the formulation.
Optimisation of liquid handling operations and sloshing control
Role of the team
Engineers build hydrodynamic models of the filling process, taking into account factors such as flow rate, liquid acceleration and container geometry, in order to determine the stages at which sloshing occurs and why. Based on these models, the team develops an active flow control system comprising intelligent valves and pumps that regulate speed and flow intensity in real time. For instance, the algorithm reduces pressure when the liquid level in the bottle approaches the neck, while increasing the flow rate during initial filling. As a result, smooth, splash-free filling is achieved. The developers test the solution in laboratory setups to select optimal filling profiles before implementing the system on a production line.
Implementation in practice
- Filling process analysis: On the operating line, flow parameters such as speed and pressure are measured, and the moments when splashes occur are recorded. This helps to identify the critical phases at which sloshing occurs.
- Computational fluid modelling: A digital model of the process is created (e.g. using CFD simulation) to reproduce the behaviour of the liquid product at different filling speeds and with different container shapes. Engineers then experiment with the model to identify correlations between the feed profile and splash formation.
- Flow profile optimisation: Based on simulations, the optimal filling speed profile is determined — for instance, a slow start followed by acceleration and a smooth deceleration towards the end of the filling process. This profile avoids sharp changes that cause splashes.
- Control system implementation: The developed profile is programmed into the pump/valve controller. High-sensitivity level sensors or flowmeters are installed and, based on their readings, the algorithm regulates the valve opening in real time to maintain the specified flow rate curve.
- Testing and scaling: The system is tested on the production line in trial mode, with controlled filling carried out on several containers and analysis of splash elimination and dosing accuracy. Following successful testing, the solution is scaled up to cover the entire production line and, if necessary, other production areas. The enterprise receives a stable filling process that is free from losses and complies with the required quality standards.