Image Fillers

Right Stuff Equipment (RSE) represents Image Fillers auger filling equipment exclusively in the Colorado and Wyoming territory. RSE sells, installs and services the full line of auger fillers that Image Fillers produces.

Being local to you means we can deliver savings on the set up and provide quick response-time for service. We also stock parts for the Image Fillers product line for customers in our territory.

Call us at 303-327-4704 or email at sales@rightstuffequipment.com to get more information.

Founding of Image Fillers: Image Fillers was founded with the goal of providing high-quality, reliable filling machines to companies in need of efficient, automated solutions for their production lines. The company’s founding dates back to 1996 in Pennsylvania by Mike Kelly Sr. Today it is still a family run business with direction by his son Mike Kelly Jr.

Image Filler produces semi-automatic fillers as well as automatic auger filler systems. Both types are available with clutch brake and servo motors with different user interfaces. In our territory RSE works closely with Image Fillers for all types of installations. RSE has a wide variety of OEMs we integrate auger fillers with, to create entirely automated filling lines. Food, nutraceutical and pharmaceutical, chemical and agricultural make up the majority of the segments where these auger fillers are installed.

Expansion of Product Line and Technological Advancements

• Technological Integration: As the demand for automation grew in the packaging industry, Image Fillers adapted by integrating advanced technologies like servo-driven motors, automated controls, and vision systems into their machines. These innovations helped their customers improve fill accuracy, reduce waste, and speed up production processes.

• Customized Solutions: Image Fillers quickly became known for their ability to offer customized filling solutions to meet the specific needs of various industries. Today, the company designs and builds auger base filling machines that handle a variety of products, including, powders, granules and some liquids, creams, with a focus on versatility and efficiency.

Semi Automatic Fillers

Application

Products: Free flow and non-free flow powders.
Materials: Pouches, jars, tubs, bags

A semi-automatic powder filler operates similarly to a fully automatic system but with more manual involvement during the process. This type of machine is commonly used in smaller-scale or low-to-medium production environments, where the operator plays a hands-on role in overseeing and adjusting the filling process. Here’s how it generally works:

Powder Supply Hopper

• Loading the Powder: The powder to be filled is placed into a hopper at the top of the machine by the operator. This hopper holds the powder before it is dispensed into containers.
• The hopper may be manually filled or have a basic feeder to maintain a steady supply of powder for the auger.

Auger Mechanism

• Auger Screw: Like a fully automatic system, the semi-automatic powder filler uses an auger tooling set to move powder from the hopper. The auger rotates and scoops up the powder in precise amounts, controlling the flow into the containers. An informative video on tooling is below.
• The operator can adjust the auger’s speed or rotation time to control the amount of powder dispensed, but the auger is responsible for the actual movement and transfer of the powder.

Manual Control of Filling

• Manual Triggering: In a semi-automatic system, the operator typically initiates the filling process. This can be done by manually pressing a button, activating a foot pedal, or using a lever to start the auger’s movement and powder dispensing.
• The operator must position the containers under the auger and may need to adjust them between fills.
• While the auger controls the amount of powder dispensed, the operator ensures the containers are properly aligned and may monitor the filling process to ensure accuracy.

Weighing & Accuracy

• Many semi-automatic systems have weighing mechanisms (like load cells) to help ensure that the correct amount of powder is dispensed. However, these systems may not be as continuous or automatic as in fully automated systems.
• Operators may manually adjust the settings to compensate for any slight variations in weight or volume, particularly when switching between different powders or container sizes.

Filling Process

• The container is placed under the auger, and as the operator activates the system, the auger fills the container with the pre-measured powder. Depending on the setup, the container may be tapped or vibrated slightly to help settle the powder and ensure a uniform fill.

Container Handling

• Containers (like bottles, jars, or pouches) are typically fed into the machine manually or placed on a conveyor. The operator positions them under the auger and ensures they are stable during filling.
• After the powder is dispensed, the operator removes the filled container and places an empty one under the auger for the next cycle.

Sealing and Packaging (Post-Filling)

• Once a container is filled, it is typically handed off to another manual process for sealing (such as capping or heat sealing) and packaging.
• This stage may still involve some operator intervention.

Control System

• Semi-automatic powder fillers have simpler control systems compared to fully automatic versions. Operators use a manual control panel or user interface to start, stop, and adjust the auger speed, filling volume, and other parameters.
• The system may have some basic sensors to alert the operator of issues like powder clogs or the need for a refill.

Cleaning and Maintenance

• Like fully automatic systems, semi-automatic fillers are designed for cleaning, although it’s often more hands-on. The operator may need to disassemble certain parts of the machine for thorough cleaning between powder changes to avoid contamination.
• Regular maintenance, such as checking the auger for wear and tear, may also be required

Fully Automatic Fillers

Application

Products: Free flow and non-free flow powders.
Materials: Pouches, jars, tubs, bags

A fully automatic auger powder filler is a machine designed to precisely dispense powders into containers (like bottles, pouches, or jars) in a high-speed, automated fashion. It uses an auger screw mechanism to measure and fill the powder, with minimal human intervention required. Here’s a breakdown of how it works:

Powder Supply Hopper

• Initial Loading: The powder to be filled is loaded into a hopper at the top of the machine. This hopper is typically large and ensures a steady supply of powder for the filling process.
• Feed System: Depending on the system, the powder may either flow into the auger system under gravity or with the help of a feeder that ensures an even flow of powder.

Auger Mechanism

• The core of the system is the auger tooling (a rotating helical screw). As the auger rotates, it meters a precise amount of powder from the hopper.
• The auger is designed to move the powder in a controlled manner, ensuring the correct portion is taken every time. The size of the auger and the rotation speed designed for the proper amount of powder needed for each fill as well as the properties of the powder.

Controlled Discharge

• Once the auger has meters the correct amount of powder, it is discharged into the container below.
• The design of the auger allows it to provide a consistent, accurate amount of powder, reducing errors and ensuring uniformity.

Container Handling

• Containers (such as bottles, pouches, or jars) are automatically fed into the system using conveyors or an automatic indexing system.
• The containers are positioned directly under the auger’s discharge point, ensuring the powder is accurately dispensed into each one.
• The container may also be vibrated or tapped slightly to settle the powder, making sure it fills the container evenly.

Key Differences from Fully Automatic Systems

• Manual Involvement: In a semi-automatic system, the operator is involved in loading, positioning containers, and starting/monitoring the filling process. There’s less automation of these tasks compared to fully automated systems.
• Weighing and Dispensing Control: While fully automatic systems continuously measure and adjust the fill amount, semi-automatic machines rely more on the operator to monitor and ensure accurate filling.
• Speed and Scale: Semi-automatic fillers are generally slower than fully automatic machines and are more suited to smaller production runs or situations where flexibility and manual oversight are beneficial.

In summary, a semi-automatic powder filler combines automated dispensing with manual intervention. The operator controls key aspects of the process, such as starting the filling, adjusting settings, and monitoring accuracy, while the auger mechanism does most of the powder dispensing work. This makes the semi-automatic filler a versatile and cost-effective option for businesses with moderate production needs.