Three Problems with Bottle Filling

If you’ve never managed a bottle filler assembly line, you probably don’t know much about troubleshooting these setups, and you probably don’t care too much, either – but when you’re on the front lines trying to keep QA up, the “how” is a really big deal!

It’s a specialized kind of system, and there’s a craft to managing these types of industrial processes to make sure they’re not just done, but done well. It’s like a lot of other things in manufacturing – quality is important.

Here are some of the biggest issues that you may have trying to micromanage a bottle filling process with matrix bottle fillers and other assorted tools.

Inconsistent Fills

One of the most commonly reported problems with bottle filling are inconsistent fills – maybe bottles are only getting half or two-thirds full, or every fourth or fifth bottle has a lower level of liquid in it. Inconsistency is a problem and jeopardizes quality assurance, so there’s a good chance it’s going to come up, either in meetings or on paper, often when it’s least convenient.

The inconsistent filling can be caused by many things. It’s a good idea to check the seal because bad seals can have an effect on these systems, and the pressure in the supply tank may also make a difference.


Overfilling is one of those nightmare problems that you experience as a line manager because, in addition to inconsistency, you have a big old mess. Anytime a bottle gets overfilled, there’s something wrong with either the speed and delivery or the calibration of the nozzle or something else. You want to look at the system visually and see why more than the allotted volume is coming into a particular container. Timing can be a major issue here.


In the world of bottle filling, foaming is a slightly different problem that has to do with the trajectory and velocity of delivery, as well as the source material itself. Again, you can check the pressure in the supply tank and things like temperature, which may make a difference as well.

In general, you can look at mean time before failure or MTBF, which will show you the ‘bathtub curve’ on how equipment stands up to time and pressure. You can also fine-tune nozzle calibration and more. For more, check out our website. At Rocky Mountain PLC, we have the quality of products and the experience to help you to sort out any troubling problems with your bottle filling line.

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