Federal Net Weight Monoblock Filling System

Will Casey, Vice President and General Manager of Federal Mfg, presents a net weight monoblock filling system integrated with a Zalkin capper. This innovative machine was showcased at Pack Expo Las Vegas 2021, alongside our inline net weight filler-lidder for large containers. The Federal Net Weight Filler guarantees accuracies of ±0.1%, making it ideal for liquid filling applications in industries like paints, agricultural chemicals, and more.

Hello, I'm Will Casey, Vice President and General Manager of Federal Manufacturing. Today, I’m excited to introduce our latest net weight monoblock filling system, specifically designed for the paint industry. This machine is optimized for handling gallon cans, but we also offer formats for five-gallon pails, quarts, and smaller containers. Our machines are engineered for accurate filling and efficient processing, using Beckhoff controls to achieve these results.

Our systems operate on net weight filling technology, which begins by taring the container and then weighing the fluid as it fills, ensuring precise measurements. This method is perfect for high-value fluids as it minimizes product giveaway. We’ve partnered with Beckhoff for their control systems because of their superior speed, accuracy, and the use of off-the-shelf components in an integrated system. By keeping all controls onboard, we reduce signal delays and enhance the speed and accuracy of the filling nozzle’s decision-making process.

We guarantee fill accuracies within ±0.5%, and often, we achieve even better precision. One of the standout features of the Beckhoff system is the stainless steel HMI units, offering a user-friendly interface with large touchscreens for simple operation.

This machine features two-stage filling, where the valve opens slowly initially, then fully, to control the flow rate and ensure accuracy while preventing splashes and mess.

For the first time in the paint industry, we have integrated a monoblock filling system. Lids are delivered via an air bay to a pick-and-place system provided by our sister company, Zalkin. This system positions and applies the exact pressure needed to secure the lid onto the container. Whether the container is accepted or rejected based on weight, it will always be lidded, preserving the product and preventing spills.