CDF Blog

    Bag-in-Box Filling Procedures and Equipment

    Comparing Fully and Semi-Automatic Filling Options

    Having a keen interest in the latest packaging industry trends, you already know the many benefits the innovative bag-in-box packaging provides for the transport, storage, and dispensing of liquid products across several industries, including food and beverage, chemical, cosmetics, and lubricants and greases. Depending on your packaging needs and capabilities, you’re probably wondering if you can automate fill lines for either pillow or form-fit bags. The good news is you can automate the processes for filling both types of bags, and there’s more than just one option to choose from.

    Bag-in-Box Filling Systems

    Why Would a Filling System or Equipment Benefit You?

    Sure, the bag-in-box packaging has already improved numerous processes, but have you reached its full potential? Success in liquid packaging depends on performance and reliability. By automating BIB filling, you optimize your efficiency by:

    • Preventing over and underfilling
    • Keeping consistency and high-quality the same across all the production lines
    • Increasing the speed and reducing manual labor involved

    Following these considerations, it’s worth taking a look at the options that are available for the bag-in-box filling systems.


    Semi-Automatic Filler

    The semi-automatic filler is a BIB filler capable of filling a wide range of Semi-Automatic Bag-in-Box Fillershelf-stable or extended-life products up to 25 liters. What makes this bag-in-box filling system semi-automatic is the need for the presence of an operator. The operator needs to place each bag in the filler, start the filling operation, then place the filled bags into the boxes manually. However, the semi-automatic filler takes care of filling the bag with the liquid according to the fill limit and the capacities set, as well as capping the bag when the fill is completed.

    This filler option allows for increasing the production levels up to three 20-liter bags per minute, which is significantly higher than manual filling. In addition, the semi-automatic filler is specifically made for filling liquid-flexible packaging and adds the touch of consistency throughout all the production lines. But that isn’t all; semi-automatic fillers can also be used to fill drum and tote fillers, as well as bag-in-box. It is the ideal choice for applications where the production goals can be met with a slower throughput.

    Fully Automatic Filler

    The fully automatic filler is a compact web-fed, fully auto-filling machine capable of filling a wide range of shelf-stable or extended life products up to 25 liters. As the name suggests, it fully automates all of the processes required for bag-in-box packaging, namely:

    • FillingBag-in-Box Fully-Automatic Filling System
    • Separating
    • Pulling the next bag into position
    • Inserting the filled bag into a box

    Having the ability to fill a container without operator interference requires minimal labor usage. To begin, the system locates the first bag, and using data from the preset fill and tolerance levels, the filler begins pouring the liquid into the bag. As the bag fills, the system rises out of the bag and shuts the lid. When the filling has been recorded, the system pulls the next bag and repeats the process. Once the bags are filled to their tolerance levels, the system begins placing the bags into boxes, all without any human involvement.  

    Fully automatic fillers have the capacity to produce six 20-liter bags per minute, which is twice as much volume as the semi-automatic fillers provide. Drums, totes, or other fillers—a fully automatic system can be designed to run multiple sizes with minimal changeover. This equipment can truly make production line cutting edge.  

    Making the Right Choice

    Whether you want to go fully automatic and skyrocket the speed of production or consider meeting production goals with having less manual labor input, CDF provides a full-service approach in selecting the proper film and fitment, sizing the box, and selecting procuring filling equipment. We often work with companies that started out using manual fill stations, and progress to fully and/or semi-automatic lines with us, or switch them over to our filling lines from their fully or semi-automatic set-ups. CDF also works with customers to create custom filling lines.

    Both the semi-automatic and the fully automatic fillers have clean-in-place and sterilize-in-place features and can be steam-sterilized as well. Both systems are:

    • Constructed of stainless steel
    • Extremely user-friendly
    • Have a very compact footprint
    • Designed specifically for filling liquid-flexible packaging

    CDF1 Smart Seal Technology optimizes precision and consistency through monitoring time, temperature, and pressure of each seal on every liner to ensure consistency of the process. Along with in-process testing procedures, this provides a high-quality, reliable product every time. Some of the tests that are performed to ensure the high-caliber standards are satisfied are:

    • Tensile and elongation
    • Dimensional compliance
    • Hydrostatic fitment
    • Inflation
    • Visual inspection

    If you’ve been thinking about upgrading your current filling application to a system that is designed for that purpose—now is the time. Changing a long-standing status quo can be a daunting challenge, so if you are concerned over the feasibility of integrating the new solution with your current set up, give us a call or reach out to us.

    We’ll provide a free consultation and help you make the right choice that best fits your needs. 

    Explore your upgrading options today to save time and money, increase throughput, and ensure high-quality production. 

    Contact a Specialist Now!



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