Automatic Dessicant Filling machine
Automatic Dessicant Filling machine
2026-02-03
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Automatic Dessicant Filling Machine: A Comprehensive Analysis of Technology, Application and Industrial Value
1. Introduction
In the modern industrial manufacturing and product packaging system, moisture control has become a key link to ensure product quality, extend shelf life and maintain performance stability. Dessicants, as core materials for absorbing moisture and regulating environmental humidity, are widely used in food, pharmaceutical, electronic manufacturing, insulating glass, precision instruments and other fields. The traditional manual or semi-automatic desiccant filling method has problems such as low efficiency, large filling error, easy material waste, high labor cost and difficulty in meeting large-scale standardized production. Against this background, the Automatic Dessicant Filling Machine, as an automated equipment integrating mechanical, electrical, pneumatic, sensing and intelligent control technologies, has gradually replaced traditional processes and become an indispensable core equipment in the desiccant application and packaging industry chain.
This paper systematically combs the core connotation, working principle, structural composition, technical parameters, application scenarios, core advantages and market development trends of the Automatic Dessicant Filling Machine, and deeply analyzes its technological innovation path and future development direction, aiming to provide a comprehensive reference for industrial practitioners, equipment R&D personnel and market investors, and clarify the important value of this equipment in promoting industrial automation upgrading and quality improvement.
2. Definition and Classification of Automatic Dessicant Filling Machine
2.1 Core Definition
The Automatic Dessicant Filling Machine is a special automated mechanical and electrical integration equipment that can automatically complete the processes of desiccant feeding, metering, filling, sealing (partial models), detection and rejection without manual intervention. It takes desiccant (including silica gel, molecular sieve, montmorillonite, calcium chloride and other granular, powdery or columnar desiccants) as the processing object, and realizes precise, efficient and standardized filling operations for different containers (such as insulating glass aluminum spacer frames, food and pharmaceutical bottles, electronic product packaging boxes, desiccant small bags, etc.) through programmable logic controller (PLC) control, servo drive and sensing detection technology, so as to meet the moisture-proof needs of various industrial products.
2.2 Main Classification
According to different application scenarios, processing objects and functional configurations, Automatic Dessicant Filling Machines can be divided into the following categories:
2.2.1 Classified by Application Field
- Insulating Glass Special Dessicant Filling Machine: Mainly used for filling molecular sieve desiccant into aluminum spacer frames or stainless steel spacer frames of insulating glass. It integrates automatic drilling, filling and sealing functions, and can adapt to spacer frames of different sizes (from 300mm×250mm to 2000mm×2000mm) and specifications (5.5-26.5mm in width). Typical models include LJGZ2020 series and ARL-45F, which are core equipment in the insulating glass deep processing industry.
- Packaging Line Dessicant Inserting/Filling Machine: Applied to food, pharmaceutical, health care products and electronic product packaging lines, mainly for inserting desiccant bags, columnar desiccants or filling loose desiccants into bottles, boxes and bags. It can be seamlessly connected with filling, capping, labeling and other equipment to form a fully automated packaging production line, such as ZONESUN ZS-PD1 and Rx-Desiccant series.
- Desiccant Bag Automatic Filling Machine: Specialized in the production of small desiccant bags, realizing automatic film feeding, metering and filling of desiccant, heat sealing, cutting and other processes, suitable for mass production of small-package desiccants (such as 1g, 5g, 10g specifications), with a production speed of up to 20-100 bags per minute.
2.2.2 Classified by Automation Degree
- Fully Automatic Dessicant Filling Machine: Realizes unmanned operation in the whole process, with functions such as automatic feeding, automatic metering, automatic filling, automatic fault detection, automatic rejection of unqualified products and automatic material replenishment. It is equipped with a touch human-machine interface (HMI) and PLC control system, and can store multiple production recipes to meet flexible production needs.
- Semi-Automatic Dessicant Filling Machine: Needs manual assistance in partial links (such as manual placement of containers, manual feeding of desiccants), and the core filling and metering links are automated. It has a small footprint and low cost, and is suitable for small-batch and multi-variety production scenarios.
2.2.3 Classified by Filling Form
- Granular/Powder Dessicant Filling Machine: For granular (such as silica gel particles, molecular sieve) and powdery desiccants, it adopts vibration feeding, spiral metering or gravity metering to ensure the accuracy of single filling, and is equipped with an anti-dust device to avoid material flying.
- Columnar/Block Dessicant Filling Machine: Aims at columnar or block desiccants, adopts mechanical clamping and pushing structure, realizes precise insertion into containers, and is equipped with infrared counting and detection functions to avoid missing filling or multiple filling.
- Desiccant Bag Inserting Machine: For pre-made desiccant bags, it completes automatic cutting, conveying and inserting into packaging containers, with a high-speed cutting structure to avoid bag breakage and desiccant leakage.
3. Working Principle and Structural Composition
3.1 Core Working Principle
The Automatic Dessicant Filling Machine takes the PLC control system as the core, and realizes the coordinated operation of each mechanism through the combination of pneumatic, servo drive and sensing detection technology, and completes the whole process of desiccant filling in accordance with the preset program. The basic working process is as follows:
First, the desiccant is stored in the feeding hopper, and the automatic feeding mechanism (vibration feeder, spiral conveyor or pneumatic conveying device) transports the desiccant to the metering unit according to the set flow rate. The metering unit adopts high-precision sensors (infrared counting sensor, weighing sensor, volume metering sensor) to measure the desiccant, ensuring that the single filling amount meets the process requirements. Then, the positioning mechanism fixes the container (insulating glass spacer frame, packaging bottle, etc.) at the designated filling position, and the filling head moves to the filling port under the drive of the servo motor to complete the desiccant filling. For insulating glass special models, after filling, the automatic sealing mechanism uses butyl rubber to seal the drilling hole to prevent desiccant leakage and moisture intrusion; for packaging line models, after filling/inserting, the detection mechanism checks for missing filling, broken bags and other problems, and the unqualified products are automatically rejected, while the qualified products enter the next process. In addition, the machine is equipped with a material level sensor, which triggers an alarm and starts the automatic replenishment function when the desiccant is insufficient, ensuring the continuity of production.
The whole process is controlled by the PLC system, and the operating parameters (filling amount, filling speed, filling height, sealing time, etc.) can be adjusted and set through the touch screen, and the production data (production quantity, qualified rate, fault information, etc.) can be recorded and displayed in real time to realize intelligent management of the production process.
3.2 Key Structural Composition
The Automatic Dessicant Filling Machine is a complex system integrating multiple modules, and its core components directly determine the equipment's performance, stability and filling accuracy. The main structural modules are as follows:
3.2.1 Control System Module
As the "brain" of the equipment, it mainly includes PLC controller (mostly imported brands such as Siemens and Omron), touch human-machine interface (HMI), relay, contactor and other electrical components. The PLC system is responsible for receiving signals from sensors, issuing execution instructions to drive mechanisms, and realizing logic control of the whole process; the touch screen provides a human-computer interaction platform, which can set process parameters, store production recipes, monitor operating status and query fault information, and supports multi-language switching to adapt to different regional use needs.
3.2.2 Feeding and Metering Module
This module is the core to ensure filling accuracy, including feeding hopper, automatic feeding mechanism (vibration feeder, spiral propeller, pneumatic conveying pipeline), metering unit and material level detection sensor. The feeding hopper is usually made of food-grade or industrial-grade stainless steel, with a large capacity (standard 5L, optional 20L) to reduce the frequency of manual feeding; the metering unit adopts different forms according to desiccant types: granular desiccant uses infrared counting or volume metering, powdery desiccant uses spiral metering or weighing feedback metering, and desiccant bags use fixed-length cutting metering. The material level sensor monitors the residual amount of desiccant in real time, and sends an alarm signal when the material is insufficient to realize automatic replenishment.
3.2.3 Filling and Execution Module
Including filling head, servo drive mechanism, positioning fixture, pneumatic cylinder and other components. The filling head is designed with anti-drip and anti-blocking structure, and the filling height can be adjusted automatically according to the container size; the servo drive mechanism ensures the precise movement of the filling head, with a positioning accuracy of up to ±0.1mm; the positioning fixture can be quickly replaced to adapt to containers of different shapes and sizes (round, square, rectangular, etc.), realizing tool-free quick changeover. For insulating glass models, this module also includes an automatic drilling mechanism and a sealing mechanism, which can complete drilling and butyl rubber sealing synchronously with filling.
3.2.4 Detection and Rejection Module
Equipped with a variety of sensors (infrared sensor, photoelectric sensor, pressure sensor, weighing sensor), it realizes real-time detection of filling status, including missing filling detection, filling amount detection, desiccant bag breakage detection, container in-place detection, etc. When unqualified products are detected, the system immediately sends a signal, and the rejection mechanism pushes the unqualified products to the designated area to ensure that only qualified products enter the next process. At the same time, the module has fault self-diagnosis function, which can quickly locate faults such as motor abnormality, sensor failure and air pressure shortage, and display fault codes on the touch screen to facilitate maintenance.
3.2.5 Frame and Protective Module
The frame is made of high-strength aluminum alloy or stainless steel, with industrial plastic spraying treatment on the surface, which has the characteristics of corrosion resistance, wear resistance and easy cleaning; the protective module includes safety grating, emergency stop button, protective cover and other devices, which meets the industrial safety standards, prevents operators from contacting the moving parts, and ensures the safety of operation.
4. Core Technical Parameters and Performance Indicators
The technical parameters of the Automatic Dessicant Filling Machine are the key basis for measuring its performance and selecting models. Different types of equipment have different parameter standards, and the common core technical parameters and performance indicators are as follows:
4.1 Basic Operating Parameters
- Power Supply: AC 110V/220V/380V, 50/60Hz, power range from 500W (small packaging line models) to 2.5KW (insulating glass large models);
- Air Pressure Requirement: ≥0.65MPa, air consumption is 2-5CFM@90PSI, equipped with air filtration and pressure regulation device to ensure stable pneumatic operation;
- Production Efficiency: Packaging line models can reach 10-150 bottles per minute (BPM), insulating glass models can complete filling of a 1m×1m spacer frame in about 30 seconds, and desiccant bag models can produce 20-100 bags per minute;
- Adaptable Container/Spacer Size: Insulating glass models: minimum 300mm×250mm, maximum 2000mm×2000mm, spacer width 5.5-26.5mm; packaging line models: suitable for containers with a neck diameter of more than 2 inches, height of 1-12 inches, and desiccant bags with a size of ≤150mm×35mm;
- Adaptable Desiccant Specifications: Granular diameter 0.5-1.5mm (molecular sieve, silica gel), columnar desiccant of various lengths, desiccant bags of 1-50g specifications.
4.2 Precision and Stability Indicators
- Filling Accuracy: ±1%-±3% (for granular/powdery desiccant), counting accuracy of columnar desiccant/desiccant bags up to 99.9%;
- Positioning Accuracy: Servo drive positioning accuracy ±0.1mm, ensuring that the filling head is accurately aligned with the container filling port;
- Operating Stability: Continuous operation time of more than 24 hours, fault rate ≤0.5%, and the service life of core components (servo motor, PLC) is more than 5 years;
- Sealing Performance: For insulating glass models, the butyl rubber sealing is tight, with no desiccant leakage and air leakage rate meeting the insulating glass industry standards; for desiccant bag models, the heat sealing strength is uniform, with no bag breakage and desiccant leakage.
4.3 Intelligent and Humanized Parameters
- Recipe Storage Capacity: Can store 50-100 groups of production recipes, realizing one-key switching of different products;
- Fault Self-Diagnosis: Can identify more than 50 kinds of common faults, and display fault causes and solutions in real time;
- Data Interaction: Supports connection with MES system, realizes real-time upload of production data, and meets the needs of industrial digital management;
- Changeover Time: Tool-free quick changeover, and the time for replacing container/desiccant specifications is ≤10 minutes.
5. Application Fields and Scenario Requirements
With the continuous improvement of industrial automation level and the increasingly strict requirements for product moisture-proof performance, the Automatic Dessicant Filling Machine has been widely used in multiple industries, and each field has specific scenario requirements for equipment performance.
5.1 Insulating Glass Manufacturing Industry
As the largest application field of desiccant filling machines, insulating glass needs to fill molecular sieve desiccant into the spacer frame to absorb moisture in the interlayer and prevent glass fogging and condensation. The industry requires the equipment to have the functions of automatic drilling, filling and sealing, adapt to various shapes of spacer frames (straight, arc, special-shaped), and the filling amount of molecular sieve is accurate to ensure the service life of insulating glass (more than 15 years). At the same time, the equipment needs to be compatible with flexible spacers (such as Swisspacer) and ordinary aluminum spacers, and can realize simultaneous filling of both sides of the spacer frame to improve production efficiency.
5.2 Food and Health Care Products Industry
Food (such as snacks, dried fruits, canned food) and health care products are extremely sensitive to moisture, and desiccant bags or columnar desiccants need to be inserted into the packaging to extend the shelf life. The industry has strict hygiene requirements, and the contact parts of the equipment must be made of food-grade 316 stainless steel, with no dead corners and easy cleaning to meet GMP and food safety standards; at the same time, the equipment needs to be seamlessly connected with the existing packaging line (filling, capping, labeling), with high-speed operation capacity (up to 150BPM) and zero missing filling rate to avoid food quality problems caused by missing desiccant.
5.3 Pharmaceutical Industry
Pharmaceutical products (such as tablets, capsules, powder injections) have extremely high requirements for moisture-proof and sterile environments. The desiccant filling machine needs to meet the pharmaceutical GMP certification, with dust-proof and sterile design, and the filling process is fully enclosed to avoid cross-contamination; the filling accuracy is higher (±1%), and the equipment has functions such as real-time monitoring of filling data and traceability of production records to meet the regulatory requirements of the pharmaceutical industry. In addition, the equipment needs to adapt to various pharmaceutical packaging containers (bottles, blister boxes, cartons) and realize flexible switching of different desiccant specifications.
5.4 Electronic and Precision Instrument Industry
Electronic components, circuit boards, precision instruments and other products are prone to short circuit, rust and performance degradation due to moisture. The desiccant filling machine needs to realize precise insertion of desiccant into electronic product packaging boxes/bags, with anti-static design to avoid damage to electronic components; the equipment has high stability, no dust and particle emission during operation, and adapts to small and precise packaging containers to meet the moisture-proof needs of high-value electronic products.
5.5 Other Industrial Fields
In addition, the Automatic Dessicant Filling Machine is also used in leather, furniture, textile, chemical and other industries, mainly for filling desiccant into product packaging to prevent moisture, mildew and oxidation during storage and transportation. For these fields, the equipment focuses on cost performance, adaptability to different desiccant types and simple operation, to meet the needs of small and medium-sized enterprises for automated production.
6. Core Advantages of Automatic Dessicant Filling Machine
Compared with manual and semi-automatic filling methods, the Automatic Dessicant Filling Machine has obvious advantages in efficiency, accuracy, cost, quality and intelligence, which is the core driving force for its popularization in the industry.
6.1 Significant Improvement of Production Efficiency
The fully automatic operation mode eliminates the link of manual intervention, and the production efficiency is 5-10 times higher than that of manual filling. Taking the packaging line model as an example, the production speed can reach 150BPM, and the insulating glass model can complete the filling of hundreds of spacer frames per hour; at the same time, the equipment can run continuously for 24 hours, and the automatic material replenishment and fault self-recovery functions reduce the downtime caused by material shortage and faults, greatly improving the overall production capacity of the production line.
6.2 Guaranteed Filling Accuracy and Product Quality
High-precision metering and sensing technology ensures the consistency of filling amount, avoiding the problems of insufficient moisture-proof effect caused by less filling and material waste caused by more filling; the fully enclosed filling process prevents desiccant from being polluted by dust and bacteria, and the detection and rejection module eliminates unqualified products, ensuring that each product meets the process standards. For industries such as food and pharmaceuticals, this effectively avoids quality accidents and reduces the loss caused by unqualified products.
6.3 Significant Reduction of Production Cost
On the one hand, it reduces labor costs: a fully automatic filling machine can replace 5-8 manual operators, and only one person is needed for daily operation and maintenance, which greatly saves labor expenditure; on the other hand, it reduces material waste: the accurate metering system reduces the waste of desiccant by more than 5% compared with manual operation, and the anti-breakage and anti-leakage design of the filling head reduces the loss of desiccant bags and containers; in addition, the long service life and low fault rate of the equipment reduce maintenance costs and downtime losses.
6.4 Strong Flexibility and Adaptability
The equipment can store multiple production recipes, and realize quick switching of different desiccant types, container specifications and filling processes by adjusting parameters on the touch screen, with tool-free changeover and strong adaptability to multi-variety and small-batch production; at the same time, it can be customized according to customer needs, such as adding double filling stations, height adjustment devices, special-shaped filling functions, etc., to meet the personalized process requirements of different industries.
6.5 Intelligent Management and Compliance Improvement
The PLC control system realizes real-time monitoring of production data, automatic recording of production quantity, qualified rate, fault information and other data, which is convenient for enterprises to carry out production management and quality traceability; the equipment meets industrial safety, food hygiene, pharmaceutical GMP and other industry standards, and the safety protection and sterile design help enterprises pass relevant certifications and meet regulatory requirements.
6.6 Improvement of Working Environment and Labor Safety
The fully enclosed operation reduces dust and noise, and the safety protection devices (safety grating, emergency stop button) avoid industrial accidents caused by manual contact with moving parts; at the same time, it liberates workers from heavy and repetitive manual labor, reduces labor intensity and improves the working environment of the production line.
7. Market Development Status and Trends
7.1 Global Market Status
In recent years, driven by the rapid development of food, pharmaceutical, electronic manufacturing, insulating glass and other downstream industries, the global demand for Automatic Dessicant Filling Machines has maintained a steady growth trend. The Asia-Pacific region, represented by China, Japan and South Korea, has become the largest market due to its rapid industrialization, large manufacturing scale and continuous improvement of automation level; Europe and the United States, as developed regions, focus on high-end intelligent and customized models, with high requirements for equipment accuracy, stability and compliance; emerging markets in Latin America, Africa and the Middle East are in the stage of industrial upgrading, and the demand for cost-effective automatic filling machines is growing rapidly.
At present, the global market competition pattern is relatively clear: European and American brands (such as LiSEC, BellatRx) occupy the high-end market with advanced technology, high stability and complete after-sales service, mainly serving large enterprises in the insulating glass and pharmaceutical industries; Chinese brands (such as ZONESUN, LIJIANG Glass) have rapidly risen with cost performance, fast delivery and customized services, and have a high market share in the middle and low-end markets and emerging markets, and some high-end models have gradually entered the European and American markets.
7.2 Core Market Trends
7.2.1 Intelligent and Digital Upgrading
With the development of industrial Internet and artificial intelligence, the Automatic Dessicant Filling Machine is developing towards higher intelligence: integrating AI algorithms to realize adaptive adjustment of filling parameters (automatically optimizing filling speed and metering accuracy according to desiccant characteristics and container changes); adding digital twin technology to simulate the filling process and predict faults in advance; realizing remote monitoring, fault diagnosis and program upgrade through cloud platforms, and meeting the needs of intelligent factory management.
7.2.2 High Precision and High Efficiency
Downstream industries have higher and higher requirements for desiccant filling accuracy and production efficiency, and the equipment is developing towards higher precision (filling accuracy up to ±0.5%) and higher speed (packaging line models exceeding 200BPM); at the same time, multi-station and multi-channel synchronous filling technology is adopted to further improve production capacity, and the lightweight and compact design reduces the floor space and improves the space utilization rate of the production line.
7.2.3 Green and Energy-Saving Development
In response to the global call for energy conservation and emission reduction, the equipment is optimized in terms of energy consumption: adopting high-efficiency servo motors and energy-saving pneumatic components to reduce power and air consumption; using recyclable and environmentally friendly materials for the frame and contact parts; designing a dust recovery system to collect desiccant dust and realize material recycling, reducing environmental pollution and material waste.
7.2.4 Customization and Integration
The personalized needs of downstream industries are becoming more and more prominent, and customized equipment (such as special-shaped container filling, ultra-small desiccant filling, high-temperature resistant desiccant filling) has become a new growth point; at the same time, the equipment is developing towards integration with the whole production line, realizing seamless connection with filling, capping, labeling, testing, packaging and other equipment, and forming a fully automated intelligent production line to improve the overall automation level of the factory.
7.2.5 Compliance and Standardization Improvement
With the increasingly strict regulatory standards in food, pharmaceutical and other industries, the equipment pays more attention to compliance design: meeting GMP, FDA, CE and other international certifications, with sterile, dust-proof and anti-cross-contamination functions; establishing a complete quality traceability system, recording the whole process of equipment operation and product production, to meet the regulatory requirements of product quality traceability.
8. Challenges and Future Development Prospects
8.1 Existing Challenges
Although the Automatic Dessicant Filling Machine has achieved rapid development, it still faces some challenges in the process of industrial popularization: first, the technical level of some domestic small and medium-sized brands is uneven, and the core components (such as high-precision sensors, servo motors) still rely on imports, resulting in high production costs and weak competitiveness in the high-end market; second, the after-sales service system of some enterprises is not perfect, and the response speed to equipment faults and maintenance needs is slow, affecting the user experience; third, the adaptability to special desiccants (such as ultra-fine powder, corrosive desiccant) and special containers (such as micro containers, irregular containers) needs to be further improved; fourth, the digital transformation of small and medium-sized enterprises is slow, and the acceptance and application capacity of high-end intelligent filling machines are insufficient.
8.2 Future Development Prospects
In the future, with the continuous advancement of industrial automation, the upgrading of downstream industries and the breakthrough of core technologies, the Automatic Dessicant Filling Machine will show broader development prospects:
In terms of technology, the localization of core components will be accelerated, and domestic brands will break through the technical monopoly of foreign brands in high-precision sensors, intelligent control systems and other fields, reducing production costs and improving product competitiveness; the integration of new technologies such as 5G, machine vision and big data will further improve the intelligence level of the equipment, realizing unmanned production and full-process digital management.
In terms of application, the application fields will continue to expand, and new energy batteries, aerospace, medical devices and other emerging high-end fields will put forward new demands for desiccant filling equipment, promoting the development of the equipment in the direction of ultra-high precision, ultra-clean and special environment adaptation; at the same time, the demand for customized and personalized equipment will continue to grow, and the equipment manufacturers will shift from "standardized production" to "customized solutions" to meet the diversified needs of different industries.
In terms of market, the global market demand will maintain steady growth, and Chinese brands will further expand the international market with technological advantages and cost performance, and the global competition pattern will be more balanced; the industry will accelerate the elimination of backward production capacity, and enterprises with core technologies, complete after-sales service and strong R&D capabilities will occupy a dominant position, promoting the healthy and standardized development of the industry.
9. Conclusion
The Automatic Dessicant Filling Machine, as an important part of modern industrial automation equipment, has become a key link to ensure product quality, improve production efficiency and reduce production costs in food, pharmaceutical, insulating glass, electronic manufacturing and other industries. It integrates mechanical, electrical, pneumatic, sensing and intelligent control technologies, and realizes the transformation of desiccant filling from manual and semi-automatic to fully automatic and intelligent, with significant advantages in efficiency, accuracy, cost and quality.
At present, the industry is in a period of rapid development of intelligent and digital upgrading, and is facing both opportunities such as the expansion of downstream market demand and the breakthrough of core technologies, as well as challenges such as technical bottlenecks and market competition. In the future, equipment manufacturers need to increase R&D investment, break through the technical barriers of core components, improve the level of intelligence and customization, and improve the after-sales service system; downstream enterprises need to accelerate the pace of automation transformation, and select appropriate filling equipment according to their own production needs to improve the overall competitiveness of the industrial chain.
With the continuous progress of technology and the continuous upgrading of industrial demand, the Automatic Dessicant Filling Machine will play a more important role in the global industrial manufacturing system, and promote the high-quality development of multiple industries with more intelligent, efficient and stable performance.
The article has covered all the core dimensions of the Automatic Dessicant Filling Machine with a formal and professional tone. If you need to adjust the content focus (such as adding more case studies, simplifying technical descriptions, or expanding market data), or modify the length and style, please feel free to let me know.
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