Debunking Myths: The Reality of 3-in-1 Filling Machines

Modern packaging requires speed, accuracy, and maximum efficiency. Nowadays, the market is competitive, and all manufacturers have to look for means of optimizing production processes, lowering production expenses, and ensuring product quality. Nevertheless, choosing the appropriate filling machine may be a rather complicated task because of the information that is frequently spread among people in the industry. The process of choosing may seem confusing for many people because of the too-wide selection and the abundance of conflicting advice. As a result, people often make inappropriate investments in wrong technologies and lose the opportunity to increase the production capacity and profits.

At Mejo, having over 15 years of experience as a Professional Labeling & Packaging Solution provider, we know for sure that making the right decision is crucial. You need efficiency, reliability, and innovation, but not only fancy solutions. It is high time to sort out the myths about the 3-in-1 monoblock filling machines and understand how these systems work.

Myth 1: Monoblocks Lack Versatility for Diverse Liquids

One of the main fears of many production managers is that purchasing 3-in-1 monoblock equipment will limit their flexibility to work only with one particular type of liquid or containers of certain sizes. This misconception does not consider all the latest achievements in modern engineering at all.

Liquid filling machine concept showing fuel nozzle filling a motorcycle tank

Engineering for Product Adaptability

For instance, a high-quality unit engineered as a filling machine for beverages can seamlessly transition from filling light spring water to thicker fruit juices, viscous sauces, or even some oil-based products with minimal adjustments. This versatility is achieved through several key design features:

Key Design Versatility Features

Modular Filling Valves: In general, manufacturers provide several options of filling valves, such as gravity, pressure, piston, or flowmeter system valve, which can be replaced or modified depending on the liquid's viscosity, foaming, and volume characteristics.

Changeover Tool-less Components: There are numerous components, like star wheels, guides, and cap chucks, that can be changed very easily without any tools. Thus, changing bottles of various shapes (round, square, oval) and cap types is not a problem.
Programmable Logic Controllers (PLCs): Sophisticated PLCs have stored information about many product types with pre-configured settings for fill volume, speed, and torque, which can be selected at will by pressing just a button.

Myth 2: Maintenance is Always Complex and Costly

The assumption that having rinsing, filling, and capping processes combined in one chassis automatically leads to a maintenance nightmare is very misleading. On the contrary, it is usually quite the opposite. By integrating three different operations in one synchronized machine, manufacturers drastically cut down the number of separate drive motors, conveyors, and synchronization sensors.

Advantages of Integrated Systems

Consider the inherent advantages:

Fewer components & connections: There are fewer components in a monoblock unit when compared to three separate machines connected with each other through an intermediate conveyor belt. As a result, there are fewer possible sources of problems, which will make troubleshooting easier.
Concentration of monitoring and fault detection: Everything happens through one Human Machine Interface (HMI) and PLC control system. So, all the faults can be detected from one place, making the whole process easy to monitor and control.
Lower maintenance cost & more uptime: While there is extra care that needs to be taken during the installation and setup process, the maintenance of one monoblock unit is much simpler when compared to three separate machines. Not only does it lower maintenance costs, but it also reduces downtime, thus increasing OEE.

Reliability and Support for the Long Term

As a company that is committed to maintaining strict quality assurance and technical support services around the world, Mejo is able to assure you that our automated systems are built for reliability and are highly maintainable, hence minimizing your cost of ownership.

Feature	Single Function System	3-in-1 Monoblock
Floor Space	High (Separate units, longer conveyors)	Low (Compact footprint, integrated design)
Synchronization	Manual/Complex (Requires multiple sensors and controls)	Integrated/Auto (Single PLC, fewer points of failure)
Throughput	Moderate (Limited by transfer points)	Extremely High (Seamless transfer, optimized speed)
Energy Usage	Variable/Inefficient (Multiple motors, standby power)	Optimized/Unified (Single power source, coordinated operation)
Changeover Time	Longer (Multiple machines to reconfigure)	Shorter (Centralized control, quick-change parts)

Myth 3: Hermetic Seal Integrity is Affected by Line Speeds

The myth that the faster the line speed, the less the seal integrity is a misconception about the current 3-in-1 monoblock system technology. It is due to accurate engineering and capping technology that each and every bottle will be hermetically sealed.

The modern generation of monoblocks features innovative sealing techniques:

Induction Cap Sealing: This widely adopted technology uses high-frequency electromagnetic fields to create airtight, tamper-evident seals without physical contact with the product. The process is incredibly fast and efficient and ensures a superior seal, critical for product freshness and safety. You can learn more aboutinduction cap sealing technology on Wikipedia.
Servo-Drive Capping Heads: It is due to the intelligent engineering of such cappers that it becomes possible to control the torque while applying the caps onto the bottles. Thanks to that, you avoid either over-tightening and thus damaging your caps and bottles or, on the contrary, not tightening the cap and thus having leaks. Such caps can be screw caps, snap-on caps, and ROPP (Roll-On Pilfer-Proof) caps.
Vision Systems: Modern equipment uses vision inspection cameras to see whether the caps are put properly and make sure that there are no leaks. Non-conforming products are sorted out from the rest of the products.

If your product line produces leakages or poorly sealed bottles, the reason for that is definitely not its speed but improperly calibrated or damaged parts or out-of-date equipment in general. Modern monoblocks are engineered to provide consistent quality sealing regardless of the speed, reaching thousands of bottles per hour.

Beyond the Basics: Advanced Features of Mejo Monoblocks

While our 3-in-1 filling machines do combine the three processes into one unit, we go further beyond providing you with sophisticated features for particular industries.

Systems Clean-in-Place (CIP): There are some fields such as food & beverages, pharmaceuticals, and regular chemical products where hygiene is essential. Mejo’s monoblocks usually have integrated CIP systems that allow for automated cleaning of product contact parts of the machine without any manual dismantling of the machine.
Ability to Sterilize Fill: Should you work with products that must be manufactured under sterile conditions, we can manufacture our filling systems in accordance with your needs that will include HEPA filters, laminar flow hoods, and sterile handling of parts.
Advanced Human-Machine Interface (HMI): The convenient touch-screen HMI interface gives the operator the ability to monitor all the real-time data on the working system and its settings
Integration with Downstream Machinery: Our monoblocks can easily be integrated with other Mejo packaging machines, like an automatic labeling machine, shrink sleeve applicator, and carton erector. This way, a completely automated production line with maximum efficiency can be obtained, which will be controlled by one control system.
Customizable and Scalable: We know that every production line has its features, and therefore, we offer customized packaging systems that fit perfectly for your needs. Whatever you need – whether it's materials resistant to corrosive substances, unusual containers, or scalability in case of increasing production—our engineers can develop the monoblock for you.

Partnering for Success: Choosing the Right Manufacturer

Equipment selection involves getting through the marketing talk and evaluating capabilities and the engineering background of the company. Your machine is an investment expected to generate profit and be useful for you for many years ahead.

When evaluating potential suppliers for your next filling machine, consider these critical factors:

Manufacturer Experience and Reputation: Is the company experienced enough? The Mejo company, operating in the packaging industry for more than 15 years and having a professional R&D department and quality control systems, confirms its reliability and innovativeness.
Customization Capabilities: Do they produce customized products suitable for your needs? The best results can be achieved only with the use of a customized product.
Technical Support and Global Reach: What technical assistance do they provide? Companies providing technical assistance all over the world, offering remote diagnostics, supply of spare parts, and on-site service should be chosen.
Quality of Materials and Construction: Demand transparency regarding the materials used in the machine's construction. For instance, food-grade stainless steel is crucial for hygiene, and durable engineering plastics, such as those used for durable plastic components in moving parts, ensure longevity and resistance to wear.
Total Cost of Ownership (TCO): Besides the purchase cost, you need to evaluate other expenses related to operation, such as energy consumption, maintenance, replacement, and procurement of spare parts. A slightly increased cost of purchase of a better machine usually provides a significant decrease in TCO.

Pharmaceutical filling machine quality control with gloved hand arranging capsules

The Bottom Line on Modern Filling Efficiency

An educated choice of packaging machinery will involve disregarding marketing terms and going directly to the specification data and manufacturing capabilities of the company. Has their R&D department developed solutions to solve practical production problems? Do they provide clear, concise contactPaths for support and readily offer customized packaging solutions? These factors matter far more than a brochure's shiny finish.

Always remember that the filling machine will be a valuable asset for your business. This is because the machine must always give you profits, increase the quality of the products, and ease up operations for many years. It would not be right for you to settle for a good-enough machine when your company’s reputation is at stake. Look for factual information about the machine by comparing its specifications and asking for a FAT test. Seeing is believing, and doing due diligence will ensure that you make the right decision.