Hydroalcoholic Gel Filling Machine: Key Points in 30 Seconds
Technical summary
Filling hydroalcoholic gel (HAG) involves specific constraints related to the presence of alcohol. Alcohols are flammable, highly volatile, and their vapors can form explosive mixtures with air.
Choosing a hydroalcoholic gel filling machine is therefore not only about production speed or filling accuracy. Safety requirements must also be considered, including ATEX zoning, vapor extraction at the filling nozzle, Zener barriers, electrical continuity between metallic parts, and the selection of suitable contact materials (metals and seals).
Depending on the required production speed, several technologies can be considered: gravimetric dosing, vacuum filling, or piston dosing, with a mechanical piston often preferred when higher accuracy is required.
Why does hydroalcoholic gel filling involve specific constraints?
Hydroalcoholic gel is a specific liquid product that requires particular filling conditions. Alcohols are flammable or highly flammable. Among the most commonly used alcohols, the flash point can range up to 40°C (and sometimes 12°C). Alcohol vapors can form explosive mixtures with air.
Another important constraint is that alcohols are highly volatile. They diffuse easily into the surrounding environment, which requires specific precautions from the design stage of the hydroalcoholic gel filling line. Alcohols are also dehydrating liquids. As a result, this characteristic directly impacts the choice of contact materials, particularly the metals and seals used on the filling machine.
As a result, the INRS provides dedicated documentation on alcohol-related risks, useful for understanding the applicable safety requirements.
Hydroalcoholic gel: a variable but strategic market
Demand for hydroalcoholic gel can evolve rapidly depending on health-related contexts. The coronavirus (COVID-19) pandemic demonstrated the need for some manufacturers to quickly adapt their hydroalcoholic gel filling capacity. More broadly, regularly monitored infectious risks such as Ebola or certain hantaviruses highlight the importance of disinfectant solutions in certain health protocols.
This variability may require rapid production ramp-up or the addition of dedicated filling lines.
What requirements should you request from your machine manufacturer?
Hydroalcoholic gel filling requires specific technical safeguards. Several elements should be validated with your machine manufacturer.
Define an ATEX zoning strategy
Alcohol filling requires the definition of an ATEX zoning strategy in order to identify areas exposed to alcohol vapor risks. This step determines the overall design of the hydroalcoholic gel filling machine.
Provide vapor extraction
Alcohol vapors must be captured directly at the filling point. It is recommended to implement a vapor extraction nozzle at the filling nozzle made of stainless steel sheet to limit vapor diffusion into the surrounding environment.
Protect nearby components
Components located near the product must be adapted to hazardous environments. Certain equipment, such as load cells, should be equipped with Zener barriers.
Ensure electrical continuity
All metallic parts of the line must be electrically connected. It is important to request a grounding wiring diagram between metallic components in order to secure the installation.
Choose the right materials
Neck centering devices and supports must be made of metal. More broadly, the choice of product-contact materials (metals and seals) must be compatible with the properties of hydroalcoholic gels and solutions.
What constraints actually affect hydroalcoholic gel filling?
| Product constraint | Impact on filling | Technical requirement |
|---|---|---|
| Flammability | Fire risk | ATEX zoning |
| Explosive vapors | Explosion risk atmosphere | Vapor extraction at filling nozzle |
| Volatility | Rapid diffusion into the environment | Stainless steel vapor extraction nozzle |
| Dehydrating liquid | Product/machine compatibility | Selection of suitable metals and seals |
| Accuracy requirements | Dosing deviation | Mechanical piston |
Which filling machine should you choose according to your production rate?
The choice of a hydroalcoholic gel filling machine mainly depends on the number of units to be produced each day.
More than 14,000 units/day
A high-speed filling line, such as the 671P, becomes suitable.
Between 4,000 and 14,000 units/day
A medium-speed filling line, for example a ST69 filling-capping monobloc with labeling machine, may meet production requirements.
Between 3,000 and 6,000 units/day
In practice, two options can be considered:
- a medium-speed filling line
- two semi-automatic lines
Less than 3,000 units/day
A semi-automatic filling line, such as the ST2000 GHA, is generally appropriate.
Which parameters actually influence production speed?
The speed of a hydroalcoholic gel filling machine is closely linked to:
- the viscosity of the hydroalcoholic gel or hydroalcoholic solution
- the internal diameter of the packaging necks
In short, depending on product fluidity and container dimensions, actual performance may vary significantly.
Which technology should you choose for your hydroalcoholic gel filling machine?
Depending on the required production speed, accuracy level, packaging dimensions, product characteristics and filling volumes, several technologies can be considered.
Gravimetric dosing
Gravimetric dosing provides direct weight control and may be relevant when filling accuracy is critical.
Vacuum filling
Vacuum filling may be considered depending on product and packaging characteristics.
Piston dosing
Piston dosing is a commonly used solution.
When higher filling accuracy is required, choosing a mechanical piston is generally the preferred option.
Why are production trials essential?
To secure a hydroalcoholic gel filling project, the most reliable approach remains real production validation: request to participate in production trials.
Trials allow verification of:
- filling accuracy
- achievable production speed
- the actual behavior of the hydroalcoholic gel
- neck and packaging formats
- the efficiency of the vapor extraction system
Conclusion
In short, hydroalcoholic gel filling involves specific constraints related to alcohol content: flammability, volatility, explosive atmospheres and machine safety.
The choice of a hydroalcoholic gel filling machine must take into account both production targets and filling accuracy, as well as safety requirements such as ATEX zoning, Zener barriers, vapor extraction systems and compatibility of contact materials.
Finally, product viscosity and packaging neck diameter directly influence actual line performance.
In all cases, production trials remain a key step in securing the project.
Over the past years, MOM Packaging has supplied hydroalcoholic gel filling machines.
MOM Packaging has been designing dosing and filling machines since 1927, with historical expertise in handling liquids and fluid to viscous products.
Louis Derangère
CEO of MOM Packaging — Industrial automation engineer and expert in precision dosing.