Project Overview
DH Industries Ltd. is a leading manufacturer of household cleaning and personal care products in Ghana. As demand for bleach and laundry products continued to grow, the company needed a more efficient and reliable filling solution to increase production capacity and improve product consistency.
To meet these requirements, DH Industries partnered with King Machine to build a customized corrosion-resistant bleach filling line capable of handling multiple bottle sizes while maintaining stable filling performance.
Project Challenges
Bleach products containing sodium hypochlorite present several challenges for automated filling equipment:
1. Corrosive Liquid Handling
Bleach is highly corrosive and can damage standard equipment components over time, resulting in reduced accuracy, leakage, and increased maintenance costs.
2. Foam Generation During Filling
High-speed filling often creates foam, which can lead to overflow, product waste, contaminated bottle necks, and sealing issues.
3. Multiple Bottle Sizes
The customer required one production line capable of handling:
250ml bottles
500ml bottles
1L bottles
2L bottles
while minimizing changeover time.
4. Reliable Sealing Performance
The packaging process required both inner plug insertion and outer cap tightening to ensure product safety during storage and transportation.
King Machine Filling Solution
King Machine supplied a complete turnkey bleach filling line consisting of:
Bottle feeding table
Corrosion-resistant diaphragm pump
ZGP-20G 20-head automatic bleach filling machine
Automatic inner plug pressing machine
Automatic cap feeder
Automatic tracking capping machine
Self-adhesive labeling machine
Stainless steel collection table
Corrosion-resistant conveyor system
The line provides fully automatic operation from bottle feeding to filling, plugging, capping, labeling, and finished product collection.
Key Technologies
1. Corrosion-Resistant Design
All product-contact components are manufactured using corrosion-resistant materials, including 316L stainless steel and PTFE.
Filling valves, pipelines, pumps, and conveyor components are designed to withstand long-term exposure to sodium hypochlorite, ensuring reliable operation and reduced maintenance requirements.
2. Diving Filling Technology
To minimize foam generation, the ZGP-20G filling machine uses a diving filling system.
The filling nozzle enters the bottle and fills from the bottom upward while gradually rising with the liquid level. This reduces liquid impact, minimizes foam formation, and improves filling cleanliness.
Combined with a servo-driven dosing system, filling accuracy is maintained within ±0.2%.
3. Automatic Plugging and Capping
The production line integrates automatic inner plug insertion and cap tightening.
Tracking-type plugging and capping technology allows the sealing heads to move synchronously with the bottles, ensuring consistent sealing quality even at higher production speeds.
4. Flexible Bottle Changeover
The line supports four bottle sizes ranging from 250ml to 2L.
Quick-change components allow operators to switch between formats with minimal adjustments, reducing downtime and improving production flexibility.
Project Results
After installation and commissioning at the customer's facility in Tema, Ghana, the new filling line delivered several key benefits:
Increased Production Capacity
The 20-head filling configuration significantly improved output and supported the customer's growing market demand.
Improved Product Quality
Corrosion-resistant construction and diving filling technology reduced foam-related issues while improving filling consistency and sealing performance.
Greater Production Flexibility
The ability to handle multiple bottle sizes on a single line allows DH Industries to respond more efficiently to different product and packaging requirements.
Conclusion
This project demonstrates King Machine's experience in designing filling solutions for corrosive chemical products such as bleach and disinfectants.
By combining corrosion-resistant materials, diving filling technology, high-precision dosing, and flexible bottle handling, the company delivered a reliable turnkey bleach filling line that meets the customer's production and quality requirements.
For manufacturers of bleach, disinfectants, detergents, and other household chemical products, King Machine provides customized filling solutions designed for long-term performance and operational efficiency.
FAQs
What type of filling machine is used for bleach?
Bleach products are typically filled using corrosion-resistant liquid filling machines equipped with specialized materials such as 316L stainless steel and PTFE.
Why is diving filling important for bleach products?
Diving filling reduces foam formation by filling from the bottom of the bottle, improving filling accuracy and preventing product overflow.
Can one bleach filling line handle multiple bottle sizes?
Yes. With appropriate change parts and machine adjustments, a single filling line can process multiple bottle formats efficiently.
What materials are suitable for sodium hypochlorite filling equipment?
316L stainless steel, PTFE, and other corrosion-resistant materials are commonly used to ensure long-term durability.
What products can be filled on a bleach filling line?
The equipment can be used for bleach, disinfectants, cleaning chemicals, detergents, and other corrosive liquid products.
