Filling

What is filling?
Headspace
Types of filling
Definition of filling

• The filling process involves the transfer of product

from a supply source to a container.
• The product must be transferred in a way that
prevents air or other contaminants from entering
the container.
• The process must be carried out in a way that
meets all applicable food safety regulations.
• The process must be carried out in a way that is
consistent and repeatable.
Headspace
• is defined as the empty space above the food product inside a sealed package.
• This space is necessary to allow for expansion of the food product during heating and
cooling, and it also helps to ensure that the package is properly sealed.
• The amount of headspace is determined by the type of food product, the container size,
and the specific processing requirements.
• In general, the goal is to have the least amount of headspace possible while still
allowing for proper expansion and sealing.
• Functions
• First, it allows for expansion of the food product during the heating process.
• Second, it helps to prevent the container from bursting due to pressure build-up.
• Third, it allows for air to escape during the sealing process.
• Finally, it can help to absorb excess moisture from the food product, which can prevent
the container from becoming soggy.
• The amount of headspace varies depending on the types of food being processed,but it
is typically between 1-2inches
Types of filler heads

• In hot filling Cone-shaped filler heads are good for filling containers that have
narrow openings, while bell-shaped filler heads are better for containers with
wider openings.
• Flat-top filler heads are useful for containers with uneven or sloped openings.
• In addition to these three main types, there are also speciality filler heads
designed for specific applications, such as aseptic filling or filling containers
with irregular shapes
• For liquid filling, there are two main types: rotary fillers and linear fillers.
Rotary fillers are typically used for high-speed filling, while linear fillers are
better for low- to medium-speed filling.
• Solid pack filling typically uses gravity feed fillers, which use gravity to move
the product into the container. This type of filler is ideal for free-flowing
products, such as beans or seeds. In addition, there are also piston fillers,
which use a plunger to push the product into the container.
Types of filling
Hot filling
•Hot fillng is defined as "the process of filling a container with a product
at a temperature that is above the product's normal ambient
temperature
•The prepared food is heated to a specific temperature,typically around
180-190°F(82 -88°C) and then transfered into clean and sterilized jars
•This is done to increase the product's shelf life by inhibiting the growth
of microorganisms such as Clostridium botulinum and Salmonella which
cause foodborne illnesses.
•The product is heated to a specific temperature, which is held for a set
period of time to achieve the desired results.
•It is commonly used for high acid foods that can be safely preserved
using a water bath e.g tomatoes,green beans,corn,chilli
Solid pack filling
• Method used in canning for preserving solid or chunky foods
such as fruits, vegetables or meats.
• This method involves tightly packing the solid food items
into jars or containers,leaving the appropriate head space.
• The food is packed tightly into the jars with little or no liquid
added.
• It is often used for foods that release their own juices.
• The main benefit is that it allows the food to retain it's shape
• Other benefits are a longer shelf life and nutrients are
preserved
• Examples are relishes,berries,peaches
Liquid filling
•The process of filling a container with a liquid product using a
machine that controls the flow of liquid into the container."
• Common examples of liquid filling include the filling of
beverage bottles, condiment bottles, and sauce jars.
• Liquid filling machines are often used in the food processing
industry, as well as the chemical and pharmaceutical industries.
• The machines can be customized to fill a wide range of
container types and sizes.
• Similar to hot pack instead of adding the hot liquid to the jars
the food is fully submerged in boiling Liquid
• Commonly used for foods that are canned in jars of juice such
as apples
Types of filling
• Solid pack filling, liquid filling, and hot filling are all used in
the food processing technology field, but they each have
their own unique characteristics and requirements.
• In terms of the amount of product being filled, solid pack
filling is generally used for smaller quantities, liquid filling for
medium quantities, and hot filling for larger quantities.
• In terms of the speed of the process, solid pack filling is the
slowest, liquid filling is faster, and hot filling is the fastest.
• In terms of the temperature of the product being filled,
solid pack filling is done at room temperature, liquid filling is
done at room temperature or slightly above, and hot filling
is done at a high temperature.
References

• - Schmidt, D. M. (2007). Filling and packing

technology: A guide for the food industry. London:
Springer.
• - Pietsch, W. (2009). Filling and packaging
machines: Selection, operation, and performance.
Berlin: Springer.
• - Chaudhari, S. G., & Vasavada, P. C. (2002). Food
and beverage packaging technology. Boca Raton:
CRC Press.
• - Knorr, W. D., & Vasavada, T. A. (2003).
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