{"id":16907,"date":"2026-07-31T01:29:51","date_gmt":"2026-07-31T01:29:51","guid":{"rendered":"https:\/\/pharmamachinecn.com\/?p=16907"},"modified":"2026-04-30T02:44:19","modified_gmt":"2026-04-30T02:44:19","slug":"sop-for-liquid-filling-machine","status":"publish","type":"post","link":"https:\/\/pharmamachinecn.com\/es\/sop-for-liquid-filling-machine\/","title":{"rendered":"SOP for Liquid Filling Machine"},"content":{"rendered":"
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Standard operating procedure of Liquid Filling Machine.<\/p>

\"SOP
SOP for Liquid Filling Machine.<\/strong><\/em><\/figcaption><\/figure>

1.0 OBJETIVO:<\/strong><\/h2>

To describe the Operating Procedure of Liquid Filling Machine used for precise volumetric filling of liquid products of varied viscosity into primary containers.<\/p>

2.0 ALCANCE:<\/strong><\/h2>

This Procedure applies to the Operating Procedure of Liquid Filling Machine installed in the liquid section of the production department.<\/p>

3.0 RESPONSABILIDAD:<\/strong><\/h2>

Filling Operator & Production Technologist<\/p>

4.0 RESPONSABILIDAD:<\/strong><\/h2>

Production Head.<\/p>

5.0 PROCEDIMIENTO:<\/strong><\/h2>

5.1 Walk through the filling area and inspect the machine frame. Make sure the “CLEANED” status tag is fixed to the unit before any work starts.<\/p>

5.2 Fill out the Equipment Usage Register. Log your name, the product code, the date, and the exact time the shift began.<\/p>

5.3 Peel off the “CLEANED” status tag and mount the “UNDER PROCESS” status tag in its place.<\/p>

5.4 Request a Line Clearance from In Process Quality Assurance (IPQA). Do not proceed until a signed and dated clearance reaches you.<\/p>

5.5 Safety Requirements:<\/strong><\/h3>

5.5.1 Many liquid products contain alcohols, essential oils, or volatile solvents. Keep all ignition sources such as lighters, mobile phones, and sparking tools away from the filling area.<\/p>

5.5.2 Slippery floors are a major hazard around liquid fillers. Wipe up any spill the moment it happens and use the yellow wet floor sign until the area dries.<\/p>

5.5.3 Do not pressurize the product tank above the rated limit shown on the tank nameplate. Over pressure can rupture a fitting and spray product at high force.<\/p>

5.5.4 Keep the CIP return lines clear at all times. A blocked return line can build up pressure during the clean cycle and damage the tank.<\/p>

5.5.5 Never reach into the fill heads while the pistons or pumps are moving. The drive force on each piston can pinch or crush a finger without warning.<\/p>

5.5.6 Wear chemical resistant gloves and a splash apron when you handle product concentrates or cleaning agents. Flush any skin contact under running water for at least 15 minutes and report to the first aid station.<\/p>

5.5.7 Lift heavy product drums with a trolley or a second person. A full 200 liter drum can weigh over 200 kg and cause a back injury if handled alone.<\/p>

5.5.8 Standard PPE for this machine includes a lab coat, nitrile gloves, safety glasses, closed shoes, and a hair net. Add a face shield when you work with hot or caustic products.<\/p>

5.5.9 Complete the safety circuit audit below every week and document it:<\/p>

5.5.9.1 Isolate the machine with the main disconnect and confirm that all live lights turn off.<\/p>

5.5.9.2 Strike the emergency stop mushroom. The pumps, drive, and conveyor must all halt in one motion.<\/p>

5.5.9.3 Open each guard door in turn. The machine should drop into a safe hold state each time.<\/p>

5.5.9.4 Test the low level probe in the product tank by drawing off some liquid. The line must pause when the probe goes dry.<\/p>

5.5.9.5 Sign the Safety Audit Log after each weekly review.<\/p>

5.6 Filling Technology Selection:<\/strong><\/h3>

5.6.1 Piston Volumetric Filling:<\/b><\/strong><\/h4>

5.6.1.1 The piston filler draws a fixed volume on each stroke. This method suits thin liquids and medium viscosity products up to 5000 cPs.<\/p>

5.6.1.2 Set the stroke length on the adjuster dial. One full turn usually changes the dose by 1 mL, so move the dial in small steps.<\/p>

5.6.1.3 Piston fillers give very repeatable doses with less than 0.5% variation between bottles. Select this mode for oral suspensions, syrups, and cough mixtures.<\/p>

5.6.2 Peristaltic Pump Filling:<\/b><\/strong><\/h4>

5.6.2.1 The peristaltic pump uses rollers to squeeze a silicone tube. The product only touches the tube, not the pump itself.<\/p>

5.6.2.2 Select this mode for sterile products, small batch runs, or any product that must not contact metal parts.<\/p>

5.6.2.3 Replace the silicone tube at the intervals listed on the preventive maintenance chart. A stretched tube gives inaccurate fills.<\/p>

5.6.3 Gravity and Pressure-Time Filling:<\/b><\/strong><\/h4>

5.6.3.1 Gravity fillers rely on head pressure from a tank mounted above the fill heads. This approach suits thin water like liquids that foam easily.<\/p>

5.6.3.2 The fill volume is controlled by a timed valve rather than a metered stroke. The valve opens for a set duration to release the dose.<\/p>

5.6.3.3 Keep the tank level constant during the run. A falling level drops the head pressure and shrinks the fill volume bottle by bottle.<\/p>

5.6.4 Flow Meter Filling:<\/b><\/strong><\/h4>

5.6.4.1 The flow meter filler uses a mass or magnetic flow sensor on each fill line. The sensor counts the exact volume that passes through the nozzle.<\/p>

5.6.4.2 This mode gives the highest accuracy and adjusts automatically when product density changes. Select this mode for high value products or regulated fills.<\/p>

5.6.4.3 Calibrate each flow sensor at the start of every batch. A two point calibration at 10% and 90% of full scale is sufficient for most products.<\/p>

5.7 Product Tank and Feed System:<\/h3>

5.7.1 The product tank is a jacketed stainless steel vessel mounted on load cells. The load cells give a live weight reading of the product on hand.<\/p>

5.7.2 Connect the product supply line to the inlet port on top of the tank. Tighten the tri clamp by hand first, then finish with a wrench to the torque on the label.<\/p>

5.7.3 Set the tank jacket temperature as required by your product. Hot syrups need the jacket at 40 to 50\u00b0C to keep the viscosity low during the fill.<\/p>

5.7.4 Start the tank agitator at low speed. Gradually raise the speed to the value listed on the batch record. A quick ramp up can splash product onto the tank lid.<\/p>

5.7.5 Confirm that the low level and high level probes are active. The machine will pause the fill if either probe loses contact with product.<\/p>

5.7.6 Check the product transfer pump for leaks at the seal. A wet seal housing points to a worn mechanical seal that needs replacement.<\/p>

5.7.7 Bleed all air from the feed lines before the first fill. Air pockets in the line cause short fills and bubble formation in the finished product.<\/p>

5.8 Nozzle and Drip Control:<\/strong><\/h3>

5.8.1 The fill nozzles are the final stage before product enters the container. Each nozzle must be matched to the product viscosity and the container mouth size.<\/p>

5.8.2 Fit the diving nozzle head for foamy products. The nozzle dives below the liquid surface during the fill so the product pours without splash or foam.<\/p>

5.8.3 Set the dive speed to match the fill rate. A slow dive causes overflow. A fast dive creates bubbles at the product surface.<\/p>

5.8.4 Confirm that the anti drip valve closes fully at the end of each cycle. A leaky valve drips product between fills and contaminates the outer bottle.<\/p>

5.8.5 Inspect each nozzle tip for product buildup at the start of each shift. Dried residue can block the flow path and cause a short fill.<\/p>

5.8.6 Swap nozzle sets whenever you change container size. Using a small nozzle on a wide mouth bottle leads to splash marks on the inside wall.<\/p>

5.9 Product Changeover:<\/strong><\/h3>

5.9.1 A product changeover requires a full clean of all contact parts. Skipping any step risks cross contamination between products.<\/p>

5.9.2 Drain all remaining product from the tank through the bottom outlet. Collect any recoverable product in a labeled container for QA review.<\/p>

5.9.3 Rinse the tank, the feed lines, and the nozzles with purified water for three minutes. The rinse water must run clear at the drain point.<\/p>

5.9.4 Engage the CIP cycle from the main control panel. The cycle will run hot caustic wash, rinse, acid wash, rinse, and final water for injection rinse.<\/p>

5.9.5 Verify the conductivity reading of the final rinse water. A reading below 1.3 microsiemens per cm confirms adequate removal of cleaning agents.<\/p>

5.9.6 Swab test a sample of three contact surfaces after the CIP cycle. Send the swabs to microbiology for bioburden testing.<\/p>

5.9.7 Replace the nozzle set, tubing, and gaskets if required by the changeover matrix. Some products need new contact parts even after a full clean.<\/p>

5.9.8 Do not load the new product until QA releases the machine for use. The release comes after satisfactory results from the swab test and the rinse conductivity check.<\/p>

5.10 HMI Navigation:<\/strong><\/h3>

5.10.1 The Human Machine Interface uses a 15 inch color touchscreen mounted at operator level. The screen links to the PLC via a fiber optic cable for fast data transfer.<\/p>

5.10.2 Power up the interface with the secondary enable button after the main panel comes on. The boot sequence takes about 60 seconds.<\/p>

5.10.3 Log in with your unique user ID and password. The system assigns access rights based on your role: Operator, Technologist, Supervisor, or Engineer.<\/p>

5.10.4 The home screen displays five tiles: Batch Setup, Fill Control, CIP\/SIP, Data Trend, and Audit Trail. Tap any tile to enter that section.<\/p>

5.10.4.1 Batch Setup: holds the product code, batch number, target volume, and line speed for the current run.<\/p>

5.10.4.2 Fill Control: shows the live fill status of each head along with the pause, resume, and abort controls.<\/p>

5.10.4.3 CIP\/SIP: runs and monitors the automated clean and steam cycles between batches.<\/p>

5.10.4.4 Data Trend: plots fill volume, temperature, and tank level over the last 24 hours.<\/p>

5.10.4.5 Audit Trail: shows a tamper proof log of all operator actions, parameter changes, and fault events.<\/p>

5.10.5 The alarm bar at the top of the screen turns amber for warnings and red for critical faults. Address red alarms before the run continues.<\/p>

5.10.6 Log off the HMI at the end of your shift. The screen will lock within 60 seconds if no activity is detected.<\/p>

5.11 Production Run:<\/strong><\/h3>

5.11.1 Confirm the tank level, jacket temperature, and agitator speed all read green on the Batch Setup screen.<\/p>

5.11.2 Run five test fills in Manual mode into labeled beakers. Weigh each beaker on a calibrated balance and compare to the target.<\/p>

5.11.3 Adjust the fill parameter on the HMI if the average weight falls outside the \u00b11% tolerance. Re test until all five samples land within tolerance.<\/p>

5.11.4 Switch the machine to Auto mode once the test fills pass. Tap Start on the Fill Control screen to begin the run.<\/p>

5.11.5 Watch the first 30 filled containers at the outfeed. Inspect each one for fill level, bubble formation, and nozzle drip marks.<\/p>

5.11.6 Pull an in process sample of five containers every 30 minutes. Weigh each sample and log the result in the Batch Production Record.<\/p>

5.11.7 Monitor the Data Trend screen for any drift in fill volume. A steady decline suggests a filter is clogging or a pump seal is wearing.<\/p>

5.11.8 Report any out of spec sample to the shift supervisor at once. Do not adjust fill parameters mid run without supervisor approval.<\/p>

5.12 Rejects and Recovery:<\/strong><\/h3>

5.12.1 The machine has two reject stations along the outfeed conveyor. Each station pushes off containers that fail a specific check.<\/p>

5.12.2 The first station uses a check weigher. Any container that falls outside the upper or lower weight limit drops onto the reject tray.<\/p>

5.12.3 The second station uses a fill level camera. The camera rejects containers with air bubbles, foam heads, or low meniscus.<\/p>

5.12.4 Sort the rejected containers within one hour of production:<\/p>

5.12.4.1 Low fill containers can be topped up by hand and returned to the line after reinspection.<\/p>

5.12.4.2 Over fill containers must be emptied back into the recovery tank for blending into the next sub batch.<\/p>

5.12.4.3 Visually defective containers are set aside for QA disposition.<\/p>

5.12.5 Record the reject count by category in the Reject Log at shift end. A rising reject trend needs investigation within 24 hours.<\/p>

5.13 Shut Down Steps:<\/strong><\/h3>

5.13.1 Press Stop on the Fill Control screen. Let all containers on the conveyor clear the line before the next step.<\/p>

5.13.2 Drain the remaining product from the tank into a labeled recovery drum. Cover the drum and send it to the quarantine area.<\/p>

5.13.3 Turn the jacket heater off and let the tank cool to room temperature.<\/p>

5.13.4 Flush all product lines with purified water for two minutes to clear residual product.<\/p>

5.13.5 Drop the machine into Safe Hold mode from the HMI. This mode depressurizes the system and parks all pistons at home position.<\/p>

5.13.6 Switch off the main power at the disconnect and lock it out if the machine will remain idle overnight.<\/p>

5.13.7 Attach the \u201cPARA SER LIMPIADO\u201d<\/strong> tag on the machine.<\/p>

5.13.8 Clean the Liquid Filling Machine as per the defined cleaning SOP.<\/p>

5.14 REGISTROS:<\/strong><\/h3>

5.14.1 Equipment Usage Register.<\/p>

5.14.2 Batch Production Record.<\/p>

5.14.3 Safety Audit Log.<\/p>

5.14.4 Reject Log.<\/p>

5.14.5 CIP Cycle Record.<\/p>

5.14.6 Cleaning Record.<\/p>

6.0 ABREVIATURAS:<\/strong><\/h2>

6.1 Procedimiento operativo est\u00e1ndar:<\/strong> Procedimiento operativo est\u00e1ndar.<\/p>

6.2 IPQA:<\/strong> Aseguramiento de Calidad en Proceso.<\/p>

6.3 GARANT\u00cdA DE CALIDAD:<\/strong> Seguro de calidad.<\/p>

6.4 EPI:<\/strong> Equipo de protecci\u00f3n personal.<\/p>

6.5 CIP:<\/strong> Clean In Place.<\/p>

6.6 SIP:<\/strong> Steam In Place.<\/p>

6.7 HMI:<\/strong> Interfaz hombre-m\u00e1quina.<\/p>

6.8 PLC:<\/strong> Programmable Logic Controller.<\/p>

6.9 cPs:<\/strong> Centipoise.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>","protected":false},"excerpt":{"rendered":"

Standard operating procedure of Liquid Filling Machine. 1.0 OBJECTIVE: To describe the Operating Procedure of Liquid Filling Machine used for […]<\/p>\n","protected":false},"author":1,"featured_media":16926,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"default","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[56],"tags":[],"class_list":["post-16907","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-packaging-equipment"],"acf":[],"_links":{"self":[{"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/posts\/16907","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/comments?post=16907"}],"version-history":[{"count":1,"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/posts\/16907\/revisions"}],"predecessor-version":[{"id":20553,"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/posts\/16907\/revisions\/20553"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/media\/16926"}],"wp:attachment":[{"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/media?parent=16907"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/categories?post=16907"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/pharmamachinecn.com\/es\/wp-json\/wp\/v2\/tags?post=16907"}],"curies":[{"name":"gracias","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}