{"id":10667,"date":"2026-05-20T10:52:39","date_gmt":"2026-05-20T08:52:39","guid":{"rendered":"https:\/\/www.mom-packaging.com\/?p=10667"},"modified":"2026-05-20T10:59:02","modified_gmt":"2026-05-20T08:59:02","slug":"hydroalcoholic-gel-filling-machine","status":"publish","type":"post","link":"https:\/\/www.mom-packaging.com\/en\/hydroalcoholic-gel-filling-machine\/","title":{"rendered":"Hydroalcoholic Gel Filling Machine"},"content":{"rendered":"

Why does hydroalcoholic gel filling involve specific constraints?<\/h2>\n

Hydroalcoholic gel<\/strong> is a specific liquid product that requires particular filling conditions. Alcohols are flammable or highly flammable<\/strong>. Among the most commonly used alcohols, the flash point can range up to 40\u00b0C (and sometimes 12\u00b0C)<\/strong>. Alcohol vapors can form explosive mixtures with air<\/strong>.<\/p>\n

Another important constraint is that alcohols are highly volatile<\/strong>. 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<\/strong>. As a result, this characteristic directly impacts the choice of contact materials<\/strong>, particularly the metals and seals used on the filling machine.<\/p>\n

As a result, the INRS provides dedicated documentation on alcohol-related risks<\/a>, useful for understanding the applicable safety requirements.<\/p>\n

Hydroalcoholic gel: a variable but strategic market<\/h2>\n

Demand for hydroalcoholic gel<\/strong> can evolve rapidly depending on health-related contexts. The coronavirus (COVID-19<\/a>)<\/strong> pandemic demonstrated the need for some manufacturers to quickly adapt their hydroalcoholic gel filling capacity. More broadly, regularly monitored infectious risks such as Ebola<\/strong><\/a> or certain hantaviruses<\/strong><\/a> highlight the importance of disinfectant solutions in certain health protocols.<\/p>\n

This variability may require rapid production ramp-up or the addition of dedicated filling lines.<\/p>\n

What requirements should you request from your machine manufacturer?<\/h2>\n

Hydroalcoholic gel filling requires specific technical safeguards. Several elements should be validated with your machine manufacturer.<\/p>\n

Define an ATEX zoning strategy<\/h3>\n

Alcohol filling requires the definition of an ATEX zoning strategy<\/strong> in order to identify areas exposed to alcohol vapor risks. This step determines the overall design of the hydroalcoholic gel filling machine.<\/p>\n

Provide vapor extraction<\/h3>\n

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<\/strong> to limit vapor diffusion into the surrounding environment.<\/p>\n

Protect nearby components<\/h3>\n

Components located near the product must be adapted to hazardous environments. Certain equipment, such as load cells<\/strong>, should be equipped with Zener barriers<\/a><\/strong>.<\/p>\n

Ensure electrical continuity<\/h3>\n

All metallic parts of the line must be electrically connected. It is important to request a grounding wiring diagram between metallic components<\/strong> in order to secure the installation.<\/p>\n

Choose the right materials<\/h3>\n

Neck centering devices and supports must be made of metal<\/strong>. More broadly, the choice of product-contact materials (metals and seals) must be compatible with the properties of hydroalcoholic gels and solutions.<\/p>\n

What constraints actually affect hydroalcoholic gel filling?<\/h2>\n\n\n\n\n\n\n\n\n\n
Product constraint<\/th>\nImpact on filling<\/th>\nTechnical requirement<\/th>\n<\/tr>\n<\/thead>\n
Flammability<\/td>\nFire risk<\/td>\nATEX zoning<\/td>\n<\/tr>\n
Explosive vapors<\/td>\nExplosion risk atmosphere<\/td>\nVapor extraction at filling nozzle<\/td>\n<\/tr>\n
Volatility<\/td>\nRapid diffusion into the environment<\/td>\nStainless steel vapor extraction nozzle<\/td>\n<\/tr>\n
Dehydrating liquid<\/td>\nProduct\/machine compatibility<\/td>\nSelection of suitable metals and seals<\/td>\n<\/tr>\n
Accuracy requirements<\/td>\nDosing deviation<\/td>\nMechanical piston<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

Which filling machine should you choose according to your production rate?<\/h2>\n

The choice of a hydroalcoholic gel filling machine<\/strong> mainly depends on the number of units to be produced each day.<\/p>\n

More than 14,000 units\/day<\/h3>\n

A high-speed filling line<\/strong>, such as the 671P<\/strong>, becomes suitable.<\/p>\n

Between 4,000 and 14,000 units\/day<\/h3>\n

A medium-speed filling line<\/strong>, for example a ST69 filling-capping monobloc with labeling machine<\/strong>, may meet production requirements.<\/p>\n

Between 3,000 and 6,000 units\/day<\/h3>\n

In practice, two options can be considered:<\/p>\n