Windshield cleaner filling machine

Why does windshield washer fluid filling involve specific constraints?

Windshield washer fluid belongs to the category of foaming products. In practice, the behavior of the liquid depends heavily on its formulation, packaging, and filling conditions.

If the machine does not properly control the dosing process, several issues can quickly arise:

• foam overflow
• container contamination
• reduced production speed
• unstable dosing
• additional line cleaning

In this context, clean filling becomes a key challenge. In other words, the machine must not only fill quickly but also fill cleanly.

Why does windshield washer fluid foam so much during filling?

In fact, foam mainly appears when the liquid undergoes a turbulent flow during dosing.

The more turbulent the flow becomes, the more foam the product generates. Conversely, a laminar flow significantly reduces foaming and stabilizes the filling process.

The real challenge is therefore to transform turbulent flow into a more controlled and diffused flow without reducing industrial line performance.

What requirements should you request from your machine manufacturer?

To fill windshield washer fluid under the right conditions, several elements should be validated with your machine manufacturer.

Ensure clean filling

First, the machine must guarantee a high level of clean filling.

In practice, it must simultaneously manage:

• foam
• dripping at the end of dosing
• the absence of stringing
• container cleanliness

As a result, clean filling reduces product loss and limits cleaning operations.

Reduce cross-contamination risks

In addition, some technologies insert the nozzle directly into the container.

However, this approach may create a risk of cross-contamination. If a container is contaminated, the nozzle may also become contaminated and subsequently affect the following containers.

In certain industries, this risk becomes difficult to accept.

Choose a technology adapted to the actual product behavior

Finally, there is no universal nozzle capable of handling all liquids.

The right choice depends on:

• the level of foam generated
• the characteristics of the liquid
• the required production speed
• the expected level of cleanliness

That is why production trials remain essential before finalizing a technical choice.

Summary of windshield washer fluid filling constraints

Product constraint	Impact on filling	Technical solution
Highly foaming product	Overflow and unstable dosing	Orifice nozzle
Turbulent flow	Excessive foam generation	Diffused and laminar flow
Dripping at the end of dosing	Container contamination	Nozzle capillary effect
Cross-contamination risk	Batch contamination	Nozzle without intrusion into the container
Format changes	Long adjustment times	Easily removable nozzle

Windshield washer fluid filling technologies

Dive nozzles: an initial solution

Historically, dive nozzles provided an initial solution to foam-related issues.

The principle is simple: the nozzle enters the bottom of the container and gradually rises during filling.

In many cases, this method effectively reduces foam overflow.

However, it also presents several limitations.

First, it reduces production speed. Indeed, the nozzle must move down before dosing and rise again at the end of the cycle.

In addition, format changes require more adjustments. Operators must notably adjust:

• the upper nozzle position
• the lower nozzle position
• the up-and-down movement speed
• the dosing flow rate

Furthermore, some products create dripping at the end of dosing.

Finally, this technology increases cross-contamination risks. If the nozzle enters a contaminated container, it may contaminate the entire batch.

Grid nozzles: better flow control

Next, manufacturers developed grid nozzles.

Their objective is to transform turbulent flow into laminar flow. Thanks to the grids, the product foams less during filling.

In addition, the grids retain droplets through capillary action. As a result, they significantly reduce the risk of contaminating the container at the end of dosing.

In approximately 75% of cases, this technology works effectively.

However, grid nozzles sometimes reach their limits with highly foaming products.

Please note: grids are not suitable for all liquids. When used with viscous products, they may create stringing, slow down dosing, and contaminate packaging.

Orifice nozzles: the most suitable solution

Today, orifice nozzles generally represent the most effective solution for filling highly foaming products, such as certain windshield washer fluids.

Their main difference lies in one key element: the orifice restriction.

This restriction maximizes the action of the grids to achieve a diffused and laminar flow.

As a result, orifice nozzles provide several benefits:

• excellent control of highly foaming products
• no immersion into the container
• reduced cross-contamination risks
• elimination of end-of-dose dripping through capillary action
• lower cost than dive nozzles
• simplified dismantling and cleaning
• quick nozzle replacement

In this context, this technology generally offers the best balance between speed, cleanliness, and industrial simplicity.

Which parameters actually influence production speed?

In practice, several parameters directly influence the speed of a windshield washer fluid filling machine:

• the level of foam generated
• container geometry
• neck diameter
• allowable flow rate without overflow
• the nozzle technology used

As a result, poor foam control can quickly reduce the actual performance of the filling line.

Why do production trials remain essential?

Even if several windshield washer fluids appear similar, their actual behavior may vary.

That is why production trials remain essential.

They notably help verify:

• filling cleanliness
• actual foam behavior
• achievable production speed
• absence of dripping
• absence of stringing
• equipment cleanability
• process robustness

To secure your project, carry out filling trials with your product and packaging.

Conclusion

Windshield washer fluid filling involves specific constraints related to the product’s foaming behavior.

The objective is therefore not only to fill quickly. Manufacturers must also ensure clean dosing, without excessive foam, dripping, or cross-contamination.

Historically, dive nozzles and later grid nozzles improved filling performance. Today, orifice nozzles generally provide the most suitable solution for highly foaming products.

Finally, as with any industrial project, production trials remain essential to secure the technology choice.

Over the past years, MOM Packaging has supplied liquid filling machines.

MOM Packaging has designed dosing and filling machines since 1927, with historical expertise in processing liquids and fluid-to-viscous products.

FAQ – Windshield Washer Fluid Filling Machine